Ford - E 350 Van - Workshop Manual - 1995 - 1995

Factory Workshop Manual Make Ford Model E 350 Van Engine and year V8-7.3L DSL Turbo VIN F (1995) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis Diagnostic Trouble Code Chart (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis Diagnostic Trouble Code Chart (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis Diagnostic Trouble Code Chart (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0195 - P0199, ( P0196 P0197 P0198 0195 0196 0197 0198 0199 ) > System Information > System Diagnosis Diagnostic Trouble Code Chart (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0220 - P0224, ( P0221 P0222 P0223 0220 0221 0222 0223 0224 ) > System Information > System Diagnosis Diagnostic Trouble Code Chart (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0235 - P0239, ( P0236 P0237 P0238 0235 0236 0237 0238 0239 ) > System Information > System Diagnosis Diagnostic Trouble Code Chart (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0260 - P0264, ( P0261 P0262 P0263 0260 0261 0262 0263 0264 ) > System Information > System Diagnosis Diagnostic Trouble Code Chart (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0265 - P0269, ( P0266 P0267 P0268 0265 0266 0267 0268 0269 ) > System Information > System Diagnosis Diagnostic Trouble Code Chart (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0270 - P0274, ( P0271 P0272 P0273 0270 0271 0272 0273 0274 ) > System Information > System Diagnosis Diagnostic Trouble Code Chart (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0275 - P0279, ( P0276 P0277 P0278 0275 0276 0277 0278 0279 ) > System Information > System Diagnosis Diagnostic Trouble Code Chart (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0280 - P0284, ( P0281 P0282 P0283 0280 0281 0282 0283 0284 ) > System Information > System Diagnosis Diagnostic Trouble Code Chart (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis > 340 - 341 Diagnostic Trouble Code Chart (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis > 340 - 341 > Page 44 DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0380 - P0384, ( P0381 P0382 P0383 0380 0381 0382 0383 0384 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0470 - P0474, ( P0471 P0472 P0473 0470 0471 0472 0473 0474 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0475 - P0479, ( P0476 P0477 P0478 0475 0476 0477 0478 0479 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0560 - P0564, ( P0561 P0562 P0563 0560 0561 0562 0563 0564 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0565 - P0569, ( P0566 P0567 P0568 0565 0566 0567 0568 0569 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0570 - P0574, ( P0571 P0572 P0573 0570 0571 0572 0573 0574 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1095 - P1099, ( P1096 P1097 P1098 1095 1096 1097 1098 1099 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1210 - P1214, ( P1211 P1212 P1213 1210 1211 1212 1213 1214 ) > System Information > System Diagnosis DTC Chart (Part 2 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1215 - P1219, ( P1216 P1217 P1218 1215 1216 1217 1218 1219 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1265 - P1269, ( P1266 P1267 P1268 1265 1266 1267 1268 1269 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1275 - P1279, ( P1276 P1277 P1278 1275 1276 1277 1278 1279 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1280 - P1284, ( P1281 P1282 P1283 1280 1281 1282 1283 1284 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294, ( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299, ( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1530 - P1534, ( P1531 P1532 P1533 1530 1531 1532 1533 1534 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1660 - P1664, ( P1661 P1662 P1663 1660 1661 1662 1663 1664 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1665 - P1669, ( P1666 P1667 P1668 1665 1666 1667 1668 1669 ) > System Information > System Diagnosis DTC Chart (Part 3 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis DTC Chart (Part 4 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis DTC Chart (Part 4 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis DTC Chart (Part 4 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis DTC Chart (Part 4 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1750 - P1754, ( P1751 P1752 P1753 1750 1751 1752 1753 1754 ) > System Information > System Diagnosis DTC Chart (Part 4 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1775 - P1779, ( P1776 P1777 P1778 1775 1776 1777 1778 1779 ) > System Information > System Diagnosis DTC Chart (Part 4 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis DTC Chart (Part 4 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Anti-Theft Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations Anti-Theft Module: Locations Full Body View (Part 2 Of 2) The Anti-Theft Module is located at the left side of the vehicle, behind "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Anti-Theft Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations > Page 181 Anti-Theft Module: Diagrams Anti-Theft Module (C335) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Anti-Theft Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations > Page 182 Anti-Theft Module (C336) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations Remote Keyless Entry Module: Locations Full Body View (Part 2 Of 2) The Remote Keyless Entry Module is located behind LH "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations > Page 186 Remote Keyless Entry Module: Diagrams Remote Keyless Entry Module (C333) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations > Page 187 Remote Keyless Entry Module (C334) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations Remote Keyless Entry Module: Locations Full Body View (Part 2 Of 2) The Remote Keyless Entry Module is located behind LH "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations > Page 192 Remote Keyless Entry Module: Diagrams Remote Keyless Entry Module (C333) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations > Page 193 Remote Keyless Entry Module (C334) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations Power Door Lock Control Module: Locations Full Body View (Part 2 Of 2) The Memory Lock Module is located behind LH "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations > Page 197 Memory Lock Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Service and Repair ABS Main Relay: Service and Repair REMOVAL and INSTALLATION 1. Open power distribution box. 2. Locate relay in power distribution box. 3. Pull relay from ABS relay socket. 4. For installation, follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Anti-Lock Brake System Module: > 98-5A-42 > Mar > 98 > ABS System - 4WABS Lamp On/False ABS Codes In Memory Anti-Lock Brake System Module: Customer Interest ABS System - 4WABS Lamp On/False ABS Codes In Memory Article No. 98-5A-42 03/18/98 ^ BRAKES - 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) - ABS LAMP ILLUMINATED FALSE ABS CODES IN MEMORY - VEHICLES BUILT THROUGH 2/23/96 ^ LAMP - ANTI-LOCK BRAKE SYSTEM (ABS) LAMP ILLUMINATED - FALSE ABS CODES IN MEMORY - VEHICLES BUILT THROUGH 2/23/96 WITH 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) LIGHT TRUCK: 1994-96 ECONOLINE ISSUE: The Anti-lock Brake System (ABS) lamp remains on after the vehicle is started and six (6) ABS codes are stored in memory on some vehicles. This may be due to the programming in the 4WABS module. ACTION: Replace the 4WABS module with a revised module. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm the vehicle has all of the following ABS codes in memory: NOTE: NO MORE, OR LESS, OF THE FOLLOWING CODES MUST BE PRESENT FOR THIS CONCERN. ^ B1342 - ABS Electronic Control Module (ECU) failure ^ C1222 - Wheel speed mismatch ^ C1115 - Power relay output short circuit to battery ^ C1184 - System timeout ^ C1220 - Warning lamp output short circuit to battery ^ C1226 - Brake warning lamp output short circuit to ground 2. If all six (6) codes are present, refer to the 1995 Econoline Service Manual, Pages 06-09B-106 and 06-09B-107 in order to replace the ABS module. Refer to the Application Chart for correct ABS module replacement. PART NUMBER PART NAME F6UZ-2B373-BA ABS Module F6UZ-2B373-CA ABS Module F6UZ-2B373-EA ABS Module OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-7-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Anti-Lock Brake System Module: > 98-5A-42 > Mar > 98 > ABS System - 4WABS Lamp On/False ABS Codes In Memory > Page 210 OPERATION DESCRIPTION TIME 985A42A Perform Diagnosis And 0.8 Hr. Replace Anti-Lock Brake System Module DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 OASIS CODES: 206000, 301000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Anti-Lock Brake System Module: > 98-5A-42 > Mar > 98 > ABS System - 4WABS Lamp On/False ABS Codes In Memory Anti-Lock Brake System Module: All Technical Service Bulletins ABS System - 4WABS Lamp On/False ABS Codes In Memory Article No. 98-5A-42 03/18/98 ^ BRAKES - 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) - ABS LAMP ILLUMINATED FALSE ABS CODES IN MEMORY - VEHICLES BUILT THROUGH 2/23/96 ^ LAMP - ANTI-LOCK BRAKE SYSTEM (ABS) LAMP ILLUMINATED - FALSE ABS CODES IN MEMORY - VEHICLES BUILT THROUGH 2/23/96 WITH 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) LIGHT TRUCK: 1994-96 ECONOLINE ISSUE: The Anti-lock Brake System (ABS) lamp remains on after the vehicle is started and six (6) ABS codes are stored in memory on some vehicles. This may be due to the programming in the 4WABS module. ACTION: Replace the 4WABS module with a revised module. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm the vehicle has all of the following ABS codes in memory: NOTE: NO MORE, OR LESS, OF THE FOLLOWING CODES MUST BE PRESENT FOR THIS CONCERN. ^ B1342 - ABS Electronic Control Module (ECU) failure ^ C1222 - Wheel speed mismatch ^ C1115 - Power relay output short circuit to battery ^ C1184 - System timeout ^ C1220 - Warning lamp output short circuit to battery ^ C1226 - Brake warning lamp output short circuit to ground 2. If all six (6) codes are present, refer to the 1995 Econoline Service Manual, Pages 06-09B-106 and 06-09B-107 in order to replace the ABS module. Refer to the Application Chart for correct ABS module replacement. PART NUMBER PART NAME F6UZ-2B373-BA ABS Module F6UZ-2B373-CA ABS Module F6UZ-2B373-EA ABS Module OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-7-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Anti-Lock Brake System Module: > 98-5A-42 > Mar > 98 > ABS System - 4WABS Lamp On/False ABS Codes In Memory > Page 216 OPERATION DESCRIPTION TIME 985A42A Perform Diagnosis And 0.8 Hr. Replace Anti-Lock Brake System Module DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 OASIS CODES: 206000, 301000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 217 Anti-Lock Brake System Module: Locations Full Body View (Part 2 Of 2) The 4 Wheel Anti-Lock Brakes Module is located on the LH front frame rail. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Diagrams > Four Wheel Antilock Brakes 4 Wheel Anti-Lock Brakes System Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Diagrams > Four Wheel Antilock Brakes > Page 220 Rear Anti-Lock Brake System Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Description and Operation > Four Wheel Anti-Lock Brake System (4WABS) Anti-Lock Brake System Module: Description and Operation Four Wheel Anti-Lock Brake System (4WABS) PURPOSE The antilock brake electronic control module monitors the brake on/off switch and the system speed sensors to determine when the antilock brake system should be engaged. In addition, the electronic control module provides a speed signal to the Programmable Speedometer/Odometer Module (PSOM). DESCRIPTION It is an on-board diagnostic, non-repairable unit consisting of two microprocessors and necessary circuitry for their operation. These microprocessors are programmed identically. The antilock brake electronic control module monitors system operation during normal driving as well as during antilock braking. OPERATION Under normal driving conditions, the microprocessors produce short test pulses to check the electrical system without any mechanical reaction. The antilock brake electronic control module continuously monitors the speed of each wheel to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the antilock brake electronic control module signals the appropriate solenoid valve in the antilock hydraulic control unit to open or close as well as the pump motor to turn on and recycle brake fluid back to the brake master cylinder. This results in moderate pulsations of the brake pedal and pump noise which may be heard in the passenger compartment. During normal braking, the brake pedal feel will be identical to a standard brake system. Most concerns which occur to the antilock brake system will be stored as a coded number in the Keep-Alive Memory (KAM) of the antilock brake electronic control module. This means that once a code is stored, it will be retained by the antilock brake electronic control module even with the key in the OFF position. The codes can be retrieved by following the on-board diagnostic procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Description and Operation > Four Wheel Anti-Lock Brake System (4WABS) > Page 223 Anti-Lock Brake System Module: Description and Operation Rear Anti-Lock Brake System (RABS) PURPOSE The Rear Antilock Brake System (RABS) module continuously monitors the rear wheel speed with a sensor mounted on the rear axle for an impending rear wheel lockup condition during braking. The RABS Module will modulate hydraulic pressure to the rear brake cylinders to inhibit rear wheel lockup. The RABS Module has self-test capabilities much like those in other electronic control systems. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) Anti-Lock Brake System Module: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) REMOVAL 1. Disconnect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Locate antilock brake control module on ABS bracket, the bracket is located in the front left hand frame inboard liner just under the driver's seat. Disconnect 40-pin connector from antilock brake control module. 3. Remove screws retaining antilock brake control module to mounting bracket. 4. Gently slide antilock brake control module along bracket and remove antilock brake control module. INSTALLATION 1. Insert antilock brake control module into mounting bracket and install retaining screws (4). Tighten to 7-9 Nm (62-80 lb ft). 2. Install retaining screw and tighten to 7-9 Nm (62-80 lb ft). 3. Connect 40-pin connector and tighten bolt to 6-7 Nm (53-62 lb ft). 4. Connect negative battery cable. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 226 Anti-Lock Brake System Module: Service and Repair Rear Antilock Brake System (RABS) REMOVAL AND INSTALLATION Anti-Lock Electronic Control Unit 1. Remove the screws/washers that hold the antilock electronic control module to the instrument panel lower brace. Pull the antilock electronic control module off the retainer clip assembly. 2. Disconnect the wiring harness from the antilock electronic control module by depressing the plastic tab on the connector and pulling the connector off. 3. For installation, follow removal steps in reverse order, followed by a system check for proper operation. Tighten screws/washers to 2 Nm (18 lb in) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay Blower Motor Relay: Locations Auxiliary Blower Relay Full Body View (Part 1 Of 3) The Auxiliary Blower Motor Relay is located at the left rear corner of the vehicle, above wheel well. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 232 Blower Motor Relay: Locations Auxiliary High Blower Motor Relay Full Body View (Part 3 Of 3) The Auxiliary High Blower Motor Relay is located at the left rear corner of the vehicle, above wheel well. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 233 Blower Motor Relay: Locations Front Blower Relay Engine Compartment View The Blower Motor Relay is located at the LH front of engine compartment, near starter relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay Auxiliary Blower Motor Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay > Page 236 Auxiliary High Blower Motor Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Warning Buzzer Module <--> [Audible Warning Device Control Module] > Component Information > Locations Warning Buzzer Module: Locations Full Body View (Part 2 Of 2) The Warning Buzzer Module is located below LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Warning Buzzer Module <--> [Audible Warning Device Control Module] > Component Information > Locations > Page 241 Warning Buzzer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Speedometer Data Link Connector > Component Information > Locations Speedometer Data Link Connector: Locations Instrument Panel View The PSOM Data Link Connector is located behind left side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamps Module <--> [Daytime Running Lamp Control Unit] > Component Information > Locations Daytime Running Lamps Module: Locations Engine Compartment View The Daytime Running Lamps Module is located at the lower RH front of engine, near horns. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamps Module <--> [Daytime Running Lamp Control Unit] > Component Information > Locations > Page 250 Daytime Running Lamps Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Engine Compartment View The Horn Relay is located on the driver's side of the engine compartment, in engine compartment fuse box. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 254 Horn Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Cutaways Interior Lighting Module: Locations Cutaways The Illuminated Entry Module is located behind LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Cutaways > Page 259 Interior Lighting Module: Locations Except Cutaways Full Body View (Part 1 Of 3) The Illuminated Entry Module is located behind LH "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 260 Illuminated Entry Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay Trailer Backup Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 265 Trailer Battery Charge Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 266 Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 272 Power Distribution Relay: Locations Auxiliary Battery Relay The Auxiliary Battery Relay is located at the LH side of the engine compartment, below headlamp. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 273 Power Distribution Relay: Locations Trailer Backup Lamp Relay Engine Compartment View The Trailer Backup Lamp Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 274 Power Distribution Relay: Locations Trailer Battery Charge Relay Engine Compartment View The Trailer Battery Charge Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 275 Power Distribution Relay: Locations Trailer Running Lamp Relay Engine Compartment View The Trailer Running Lamp Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay Trailer Battery Charge Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay > Page 278 Trailer Backup Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay > Page 279 Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Location An engine compartment power distribution box is located near the lower left-hand fender apron. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-24 > Oct > 03 > Engine Control - Cold Temperature Hard Start/No Start Powertrain Control Module: Customer Interest Engine Control - Cold Temperature Hard Start/No Start Article No. 03-21-24 10/06/03 HARD START/NO START - EXTREME COLD AMBIENT TEMPERATURE - VEHICLES WITH 7.3L DIESEL ENGINE FORD: 1992-1996 ECONOLINE Article 97-7-7 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A hard start or no start condition in extreme cold weather may occur on some vehicles. This may be caused by fuel freezing in the delivery module draw tube. ACTION Replace Diesel Delivery Module (DDM) with a revised DDM (-9275-). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. NOTE WHEN REPLACING THE DDM, BE SURE TO CLEAN AREA AROUND FLANGE/TANK OPENING TO PREVENT PARTICULATE MATTER FROM FALLING INTO THE FUEL TANK. 2. Replace the DDM with the revised DDM (-9275-) by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. 3. Reinstall the fuel tank. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-7 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 03-21-24 > Oct > 03 > Engine Control - Cold Temperature Hard Start/No Start Powertrain Control Module: All Technical Service Bulletins Engine Control - Cold Temperature Hard Start/No Start Article No. 03-21-24 10/06/03 HARD START/NO START - EXTREME COLD AMBIENT TEMPERATURE - VEHICLES WITH 7.3L DIESEL ENGINE FORD: 1992-1996 ECONOLINE Article 97-7-7 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A hard start or no start condition in extreme cold weather may occur on some vehicles. This may be caused by fuel freezing in the delivery module draw tube. ACTION Replace Diesel Delivery Module (DDM) with a revised DDM (-9275-). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. NOTE WHEN REPLACING THE DDM, BE SURE TO CLEAN AREA AROUND FLANGE/TANK OPENING TO PREVENT PARTICULATE MATTER FROM FALLING INTO THE FUEL TANK. 2. Replace the DDM with the revised DDM (-9275-) by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. 3. Reinstall the fuel tank. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-7 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99-4-3 > Mar > 99 > PCM Reprogramming Out of Vehicle Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99-4-3 > Mar > 99 > PCM Reprogramming Out of Vehicle > Page 302 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 97-9-8 > Apr > 97 > PCM Reprogramming Tips Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 97-9-8 > Apr > 97 > PCM Reprogramming Tips > Page 307 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 99-4-3 > Mar > 99 > PCM Reprogramming Out of Vehicle Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 99-4-3 > Mar > 99 > PCM Reprogramming Out of Vehicle > Page 313 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 97-9-8 > Apr > 97 > PCM Reprogramming Tips Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 97-9-8 > Apr > 97 > PCM Reprogramming Tips > Page 318 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 319 Powertrain Control Module: Specifications PCM Retainer Nuts 3-4 Nm Wiring Connector Retaining Bolts 4 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 320 Powertrain Control Module: Locations Engine Compartment View The Powertrain Control Module is located at the left rear of the engine compartment, near brake master cylinder. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 323 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 324 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 325 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 326 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 327 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 328 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 329 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 330 Powertrain Control Module: Connector Views Powertrain Control Module (Part 1 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 331 Powertrain Control Module (Part 2 Of 2) PCM Pinout Chart PCM Pinout Chart Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 332 PCM Pinout (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 333 Part 2 Of 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 334 Part 3 Of 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 335 Part 4 Of 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 336 Powertrain Control Module: Description and Operation Powertrain Control Module (PCM) The Powertrain Control Module (PCM) retrieves inputs from various engine sensors to compute the required fuel flow rate necessary to maintain a proper air/fuel ratio throughout the entire engine operational range. The PCM also determines and compensates the vehicle's uniqueness. The system will also compensate for changes in altitude (i.e., from sea level to mountains). The 104-pin EEC-V system PCM outputs a command to the Injector Driver Module (IDM) which in turn energizes the fuel injector with up to 115V DC. The fuel injector is controlled by the in IDM to meter the appropriate quantity of fuel at the correct time and duration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 337 Powertrain Control Module: Service and Repair Powertrain Control Module REMOVAL 1. Disconnect battery negative cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Loosen engine control sensor wiring to PCM connector retainer bolt. 3. Remove engine control sensor wiring connector from PCM. 4. Remove the two PCM seal nuts and loosen left fender liner screws and remove liner or bend down to clear powertrain control module. Remove PCM. INSTALLATION 1. Follow removal procedures in reverse order. 2. Tighten PCM retainer screw to 3-4 Nm (27-35 in lb). Tighten engine control sensor wiring connector retainer bolt to 4 Nm (35 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Injector Driver Module > Component Information > Specifications Injector Driver Module: Specifications Injector Driver Module Retaining Bolt 3-4 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 341 Injector Driver Module: Locations Engine Compartment View The Injector Driver Module is located at the LH rear of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 342 Injector Driver Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 343 Injector Driver Module: Service Precautions WARNING: RED-STRIPED WIRES CARRY 115V DC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 344 Injector Driver Module: Description and Operation The Injector Driver Module (IDM) supplies 115V DC to all of the fuel injectors. The IDM receives signals from the Powertrain Control Module (PCM) for Cylinder Identification (CID) and Fuel Delivery Command Signal (FDCS). The PCM controls when the timing of the injectors should start and how long the injector is open. The IDM controls the injector firing sequence through output drivers. The IDM has an output driver for each injector: one low side driver for each injector and one high side driver for each bank of injectors. The injector is fired when the output driver closes the circuit to ground, completing the circuit ground path. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 345 Injector Driver Module: Service and Repair REMOVAL WARNING: RED-STRIPED WIRES CARRY 115V DC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. 1. Disconnect battery negative cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Remove module bolts. 3. Loosen wiring connector retainer bolt. 4. Remove Injector Driver Module (IDM). INSTALLATION 1. To install, reverse removal procedures. 2. Tighten IDM retainer bolt to 3-4 Nm (27-35 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Injector Driver Module Relay > Component Information > Description and Operation Injector Driver Module Relay: Description and Operation PURPOSE The Injector Driver Module (IDM) Relay provides power to the IDM. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Control Unit: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 354 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 355 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 356 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 357 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 358 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 359 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 360 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Customer Interest for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition Glow Plug Relay: Customer Interest Diesel Engine - Hard Start/No Start Condition Article No. 96-1-7 01/02/96 ^ HARD START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ NO START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ ENGINE - 7.3L DIT DIESEL - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 LIGHT TRUCK: 1994-95 F SUPER DUTY, F-25O, F-35O 1995 E-35O ISSUE: The glow plug relay may melt and result in a no start/hard start condition. This may be caused by the nuts on the glow plug relay losing their torque and increasing the resistance on the connections of the relay. ACTION: Increase the torque of the nuts on the glow plug relay and add a lockwasher. Refer to the following Service Procedure for details. NOTE: THIS PROCEDURE SHOULD BE ADHERED TO FOR ALL FUTURE GLOW PLUG REPAIRS ON 7.3L DIT DIESEL ENGINES. SERVICE PROCEDURE CAUTION: DO NOT USE A SCREWDRIVER OR SIMILAR TOOL TO PRY OFF THE TERMINAL COVER. BATTERY VOLTAGE IS PRESENT AT THE TERMINALS. 1. Disconnect the batteries. 2. Remove the glow plug relay plastic terminal cover. 3. Remove glow plug relay nuts. 4. Add zinc plated lockwashers (34791-S36) on top of the wire harness connectors below the upper nuts. CAUTION: ZINC PLATED LOCKWASHERS MUST BE USED. 5. Replace nuts and torque to 7.9 t0.6 N-m (70 +/- 5 lb-in). CAUTION: DO NOT OVERTORQUE. DAMAGE TO THE RELAY WILL RESULT. 6. With the addition of the lockwasher, the plastic terminal cover may not remain securely attached to the studs. Therefore, apply Silastic Sealer (F4AZ-19562-B) to the plastic terminal cover to make sure the cover remains secure. Replace the cover. 7. Reconnect the batteries. PART NUMBER PART NAME 34791-536 Zinc Plated Lockwasher F4AZ-19562-B Silastic Sealer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960107A Install Lockwashers And 0.4 Hr. Apply Increased Torque DEALER CODING Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Customer Interest for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition > Page 370 CONDITION BASIC PART NO. CODE 12B533 H4 OASIS CODES: 203000, 203200, 601300, 602300, 603300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition Glow Plug Relay: All Technical Service Bulletins Diesel Engine - Hard Start/No Start Condition Article No. 96-1-7 01/02/96 ^ HARD START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ NO START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ ENGINE - 7.3L DIT DIESEL - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 LIGHT TRUCK: 1994-95 F SUPER DUTY, F-25O, F-35O 1995 E-35O ISSUE: The glow plug relay may melt and result in a no start/hard start condition. This may be caused by the nuts on the glow plug relay losing their torque and increasing the resistance on the connections of the relay. ACTION: Increase the torque of the nuts on the glow plug relay and add a lockwasher. Refer to the following Service Procedure for details. NOTE: THIS PROCEDURE SHOULD BE ADHERED TO FOR ALL FUTURE GLOW PLUG REPAIRS ON 7.3L DIT DIESEL ENGINES. SERVICE PROCEDURE CAUTION: DO NOT USE A SCREWDRIVER OR SIMILAR TOOL TO PRY OFF THE TERMINAL COVER. BATTERY VOLTAGE IS PRESENT AT THE TERMINALS. 1. Disconnect the batteries. 2. Remove the glow plug relay plastic terminal cover. 3. Remove glow plug relay nuts. 4. Add zinc plated lockwashers (34791-S36) on top of the wire harness connectors below the upper nuts. CAUTION: ZINC PLATED LOCKWASHERS MUST BE USED. 5. Replace nuts and torque to 7.9 t0.6 N-m (70 +/- 5 lb-in). CAUTION: DO NOT OVERTORQUE. DAMAGE TO THE RELAY WILL RESULT. 6. With the addition of the lockwasher, the plastic terminal cover may not remain securely attached to the studs. Therefore, apply Silastic Sealer (F4AZ-19562-B) to the plastic terminal cover to make sure the cover remains secure. Replace the cover. 7. Reconnect the batteries. PART NUMBER PART NAME 34791-536 Zinc Plated Lockwasher F4AZ-19562-B Silastic Sealer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960107A Install Lockwashers And 0.4 Hr. Apply Increased Torque DEALER CODING Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition > Page 376 CONDITION BASIC PART NO. CODE 12B533 H4 OASIS CODES: 203000, 203200, 601300, 602300, 603300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Page 377 Glow Plug Relay: Locations Glow Plug Relay The glow plug relay is mounted on top of the engine, behind the generator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Page 378 Glow Plug Relay: Description and Operation DESCRIPTION The glow plug control module has a plastic base and two mounting bolts. It is operated by the Powertrain Control Module (PCM) which senses engine oil temperature, PCM voltage, and barometric pressure. OPERATION When the engine oil temperature or the barometric pressure is low, the PCM activates the glow plug control module and the intake manifold glow plugs. If the PCM voltage is too high, the PCM deactivates the glow plug control module and the intake manifold glow plugs immediately energize for a shorter duration, decreasing the modulation of the duty cycle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Page 379 Glow Plug Relay: Service and Repair REMOVAL 1. Disconnect the batteries. 2. Remove the plastic terminal cover from the relay. CAUTION: Do not use a screwdriver or similar tool to pry off the terminal cover. Battery voltage is present at the terminals. 3. Disconnect the battery terminal connector (12 volt power wire), the glow plug relay connector, and the harness connector. 4. Remove the mounting screws and remove the relay from the engine. INSTALLATION 1. Install the relay on the engine and tighten the screws. 2. Reconnect the harness connector, relay connector, and the battery terminal connector. 3. Reinstall the plastic terminal cover. 4. Reconnect the batteries. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement Technical Service Bulletin # 94E52 Date: 950201 Recall - Ignition Control Module Inspection/Replacement 94E52 EMISSIONS RECALL Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Dealer Letter Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Customer Notification Letter Attachment I - Administrative Instructions Administrative Instructions OASIS You must use OASIS to determine if a truck is eligible for this or another recall. Note Correct all affected dealer stock trucks before delivery. Promptly Correct Affected trucks on the enclosed list and other eligible trucks on hand or brought to your dealership. Dealer Owner Contact Immediately contact any owner of an eligible truck you know of whose name is not on the list. Give the owner a copy of the Owner Letter. Region Contact Advise FCSD regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Parts and Service Zone Manager about recall concerns. Claims Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use a Form 1863 or authorized alternative claim form as an internal repair order to support your DWE entry. Please read Section 6.3 of your Warranty and Policy Manual. This section contains claim processing information including related damage/refunds and refunds. Attachment II - Labor and Parts Information Labor Allowance Inspect the Ignition Control (IC) Module for Build Date and, if necessary, Replace the Module. Obtain, Prepare and Attach an Authorized Modifications Label. Provided California Owners With "Emissions Recall - Proof of Correction" Certificates. Claim Procedure For Dealers Not On ACES II Pilot INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 389 F-Series 0.2 Hrs. Insert in Box "A" on Form 1864 Econoline 0.4 Hrs. Insert in Box "A" on Form 1864 INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Insert in Box "B" on Form 1864 Econoline 0.5 Hrs. Insert in Box "B" on Form 1864 Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Claim Procedure for Dealers on ACES II Pilot Submit using DWE INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.2 Hrs. Labor Operation - 94E52A Econoline 0.4 Hrs. Labor Operation - 94E52A 0.1 Hrs. Misc. Expense Code "ADMIN" INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Labor Operation - 94E52B Econoline 0.5 Hrs. Labor Operation - 94E52B 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. Part Number Description F1PZ-12A297-A Module, Ignition Control (IC) For the latest part price, call or check ^ Order Processing Center ^ an updated Master Price Book ^ DOESII Excess Stock Return Excess stock returned for credit must have been purchased form Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ignition Control (IC) Module Inspection And Replacement Affected Vehicles: 1995 Model E and F-Series Trucks as follows: Kentucky Truck Plant 11/23 Thru 28, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 390 Lorain Assembly 11/22 Thru 28, 1994 Norfolk Assembly 11/22 Thru 29, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 391 1. Locate ignition control module under hood. On F-Series models, it is located on the left inner fender panel near the hood hinge. See Figure 1. On E-Series models, it is located behind the battery on the dash panel. See Figure 2. 2. On Econoline models only, disconnect and position battery out of the way. 3. Remove two screws retaining ignition control module heat-sink assembly to left fender apron. 4. Disconnect harness connector from ignition control module. 5. Inspect date code on module. If the date code is 4L18B, the module must be replaced. See Figure 3 for date code location. Continue on to next step. If not, go to step 9. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 392 6. Remove two screws retaining ignition control module to heat-sink and remove ignition control module. 7. Coat metal baseplate of the replacement ignition control module uniformly with silicone compound, approximately .0179 mm (1/31-inch) thick. Use Silicone Dielectric Compound WA-10 D7AZ-19A331-A (ESE-M1C171-A) or equivalent. 8. Position ignition control module onto heat-sink and tighten two retaining screws to 1.7-4.0 N-m (15-35 in-lb). 9. Install ignition control module heat-sink assembly useing two retaining screws, and tighten to 9-14 N-m (80-124 in-lb). 10. Connect engine control sensor wiring to the ignition control module. 11. On Econoline models only, reposition and connect battery. Start engine, verify operation. Authorized Modifications Labels And California "Emissions Recall-Proof of Corrections" Certificates ^ Obtain, prepare and attach an Authorized Modifications Label (available at no-charge {package of 25 with overlay} as part number FCS-8262 or DOES II). Write on the label "IC Module Inspected/Replaced", authority, Emissions Recall 94E52", your P&A; Code and date of repair as shown below. ^ Provide California owners with "Emissions Recall-Proof of Correction " Certificates. Authorized Modifications Decal Dealer Letter RECALL NUMBER 94E52 Date: Feb., 1995 PARTS AVAILABILITY At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers At PDC By: Now Date in Owner Letter: March, 1995 To: All Dealers Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 393 Subject: Emissions Recall 94E52 - Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Affected Vehicles Approximately 4,500 1995-model E & F-Series trucks manufactured at the Kentucky Truck Plant November 23 through 28, 1994, the Lorain Assembly Plant from November 22, through 28, 1994, and the Norfolk Assembly Plant from November 22, through 29, 1994. Reasons For Recall Some of these trucks have been built and shipped with ignition control (IC) modules which may fail and cause an engine no-start condition. Service Action The IC module will be inspected for build date and, if necessary, will be replaced. Attachments Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Owner Letter March, 1995 Serial Number: 12345678901234567 94E52 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 94E52) certain 1995-Model Econoline and F-Series Trucks. Your truck may have been manufactured with an ignition control module that may fail and cause an engine no-start condition. What The Dealer Will Do At no cost to you, your dealer will inspect the ignition control module on your truck and, if necessary, replace the module. If you do not have this service done, your Emissions Warranty may be reduced. How Long Will It Take? The time needed to repair your truck is about one-half hour. However, due to service scheduling times, your dealer may need your truck one full working day. Call Your Dealer Call your Dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When your bring your truck in, present this letter to the dealer. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address or Sold the Truck? If you have, please fill out the enclosed prepaid postcard and mail it to us. If the service for this recall is not provided promptly and without charge, talk to the dealer service manager. You may also contact the Ford Customer Assistance Center at 300 Renaissance Center, P.O. Box 43360, Detroit, MI, 48243. Please have your truck serviced promptly to maintain full Emissions warranty coverage. We regret the inconvenience this recall may cause you. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement Technical Service Bulletin # 94E52 Date: 950201 Recall - Ignition Control Module Inspection/Replacement 94E52 EMISSIONS RECALL Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Dealer Letter Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Customer Notification Letter Attachment I - Administrative Instructions Administrative Instructions OASIS You must use OASIS to determine if a truck is eligible for this or another recall. Note Correct all affected dealer stock trucks before delivery. Promptly Correct Affected trucks on the enclosed list and other eligible trucks on hand or brought to your dealership. Dealer Owner Contact Immediately contact any owner of an eligible truck you know of whose name is not on the list. Give the owner a copy of the Owner Letter. Region Contact Advise FCSD regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Parts and Service Zone Manager about recall concerns. Claims Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use a Form 1863 or authorized alternative claim form as an internal repair order to support your DWE entry. Please read Section 6.3 of your Warranty and Policy Manual. This section contains claim processing information including related damage/refunds and refunds. Attachment II - Labor and Parts Information Labor Allowance Inspect the Ignition Control (IC) Module for Build Date and, if necessary, Replace the Module. Obtain, Prepare and Attach an Authorized Modifications Label. Provided California Owners With "Emissions Recall - Proof of Correction" Certificates. Claim Procedure For Dealers Not On ACES II Pilot INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 399 F-Series 0.2 Hrs. Insert in Box "A" on Form 1864 Econoline 0.4 Hrs. Insert in Box "A" on Form 1864 INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Insert in Box "B" on Form 1864 Econoline 0.5 Hrs. Insert in Box "B" on Form 1864 Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Claim Procedure for Dealers on ACES II Pilot Submit using DWE INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.2 Hrs. Labor Operation - 94E52A Econoline 0.4 Hrs. Labor Operation - 94E52A 0.1 Hrs. Misc. Expense Code "ADMIN" INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Labor Operation - 94E52B Econoline 0.5 Hrs. Labor Operation - 94E52B 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. Part Number Description F1PZ-12A297-A Module, Ignition Control (IC) For the latest part price, call or check ^ Order Processing Center ^ an updated Master Price Book ^ DOESII Excess Stock Return Excess stock returned for credit must have been purchased form Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ignition Control (IC) Module Inspection And Replacement Affected Vehicles: 1995 Model E and F-Series Trucks as follows: Kentucky Truck Plant 11/23 Thru 28, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 400 Lorain Assembly 11/22 Thru 28, 1994 Norfolk Assembly 11/22 Thru 29, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 401 1. Locate ignition control module under hood. On F-Series models, it is located on the left inner fender panel near the hood hinge. See Figure 1. On E-Series models, it is located behind the battery on the dash panel. See Figure 2. 2. On Econoline models only, disconnect and position battery out of the way. 3. Remove two screws retaining ignition control module heat-sink assembly to left fender apron. 4. Disconnect harness connector from ignition control module. 5. Inspect date code on module. If the date code is 4L18B, the module must be replaced. See Figure 3 for date code location. Continue on to next step. If not, go to step 9. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 402 6. Remove two screws retaining ignition control module to heat-sink and remove ignition control module. 7. Coat metal baseplate of the replacement ignition control module uniformly with silicone compound, approximately .0179 mm (1/31-inch) thick. Use Silicone Dielectric Compound WA-10 D7AZ-19A331-A (ESE-M1C171-A) or equivalent. 8. Position ignition control module onto heat-sink and tighten two retaining screws to 1.7-4.0 N-m (15-35 in-lb). 9. Install ignition control module heat-sink assembly useing two retaining screws, and tighten to 9-14 N-m (80-124 in-lb). 10. Connect engine control sensor wiring to the ignition control module. 11. On Econoline models only, reposition and connect battery. Start engine, verify operation. Authorized Modifications Labels And California "Emissions Recall-Proof of Corrections" Certificates ^ Obtain, prepare and attach an Authorized Modifications Label (available at no-charge {package of 25 with overlay} as part number FCS-8262 or DOES II). Write on the label "IC Module Inspected/Replaced", authority, Emissions Recall 94E52", your P&A; Code and date of repair as shown below. ^ Provide California owners with "Emissions Recall-Proof of Correction " Certificates. Authorized Modifications Decal Dealer Letter RECALL NUMBER 94E52 Date: Feb., 1995 PARTS AVAILABILITY At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers At PDC By: Now Date in Owner Letter: March, 1995 To: All Dealers Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 403 Subject: Emissions Recall 94E52 - Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Affected Vehicles Approximately 4,500 1995-model E & F-Series trucks manufactured at the Kentucky Truck Plant November 23 through 28, 1994, the Lorain Assembly Plant from November 22, through 28, 1994, and the Norfolk Assembly Plant from November 22, through 29, 1994. Reasons For Recall Some of these trucks have been built and shipped with ignition control (IC) modules which may fail and cause an engine no-start condition. Service Action The IC module will be inspected for build date and, if necessary, will be replaced. Attachments Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Owner Letter March, 1995 Serial Number: 12345678901234567 94E52 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 94E52) certain 1995-Model Econoline and F-Series Trucks. Your truck may have been manufactured with an ignition control module that may fail and cause an engine no-start condition. What The Dealer Will Do At no cost to you, your dealer will inspect the ignition control module on your truck and, if necessary, replace the module. If you do not have this service done, your Emissions Warranty may be reduced. How Long Will It Take? The time needed to repair your truck is about one-half hour. However, due to service scheduling times, your dealer may need your truck one full working day. Call Your Dealer Call your Dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When your bring your truck in, present this letter to the dealer. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address or Sold the Truck? If you have, please fill out the enclosed prepaid postcard and mail it to us. If the service for this recall is not provided promptly and without charge, talk to the dealer service manager. You may also contact the Ford Customer Assistance Center at 300 Renaissance Center, P.O. Box 43360, Detroit, MI, 48243. Please have your truck serviced promptly to maintain full Emissions warranty coverage. We regret the inconvenience this recall may cause you. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Full Body View (Part 2 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 408 The Air Bag Module is located behind LH (Driver's Side) side of instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 409 Air Bag Control Module: Diagrams Air Bag Module (C209) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 410 Air Bag Module (C208) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 411 Air Bag Control Module: Description and Operation The air bag diagnostic monitor continually monitors all supplemental air bag restraint system components and wiring connections for possible faults in the system. If the air bag diagnostic monitor detects a fault in the supplemental air bag restraint system when the ignition switch is in the RUN position, a diagnostic trouble code will be displayed on the air bag indicator, located in the instrument cluster. Performing system diagnostics is the main purpose of the air bag diagnostic monitor. The air bag diagnostic monitor does not deploy the air bag in the event of a crash. The center and right rear air bag sensors are "hard wired" to the air bag, therefore, the center and right rear front primary crash sensors and RH cowl side panel air bag safing sensor determine when to deploy the air bag. FEATURES AND FUNCTIONS - The air bag diagnostic monitor illuminates the air bag indicator for approximately six seconds when the ignition switch is in the RUN position and then turns the indicator off. This shows that the air bag indicator is operational. If the air bag indicator does not illuminate or the indicator stays on or flashes at any time, a fault has been detected by the air bag diagnostic monitor. - Diagnostic trouble codes may not be displayed for approximately 30 seconds after the ignition switch is placed in the RUN position. This is the amount of time the air bag diagnostic monitor requires to perform all tests and verify system faults, if present. - Each diagnostic trouble code (a series of flashes and pauses of the air bag indicator) represents a two-digit number. Each diagnostic trouble code is always displayed at least twice. For example, a diagnostic trouble code 32 is displayed as three flashes, followed by a one-second pause, then two flashes, followed by a three-second pause. - If a system fault is present and the air bag indicator is malfunctioning, an audible tone will be heard, indicating that system service is required. The tone is a series of five sets of five beeps. This does not indicate a diagnostic trouble code 55. If the tone is heard, the air bag indicator is inoperative and a system fault that requires service is present. - If a fault exists that makes unwanted air bag deployment possible, the air bag diagnostic monitor has an internal thermal fuse that will blow (open) automatically. This removes all power to the air bag deployment circuit. CAUTION: The thermal fuse does not blow (open) because of excessive current flowing through it. DO NOT attempt to jumper out the thermal fuse with a circuit breaker or any other type of fuse. - The air bag indicator will flash the appropriate diagnostic trouble code to indicate the suspect circuit. If the indicator is malfunctioning the tone will be heard. - Diagnostic trouble codes are prioritized numerically so if two or more different faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. - The air bag diagnostic monitor includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event the battery or battery cables are damaged in an accident before the center air bag and front air bag sensors close. The backup power supply will deplete its stored energy approximately one minute after the positive battery cable is disconnected. WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT SERVICE IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY POSITIVE CABLE AND WAIT ONE MINUTE. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 412 Air Bag Control Module: Service and Repair CAUTION: When servicing the air bag diagnostic monitor with a blown internal fuse (DTC 51), find and repair all wire damage or shorts. A blown air bag diagnostic monitor can be used to find electrical faults without replacing components unnecessarily. The diagnostic procedures are written to give safety first priority. The following steps may be taken to find the cause that initiated a blown fuse: 1. Verify the system using the old air bag diagnostic monitor and verify the wiring repairs success before proceeding. Repeat as many times as required. 2. Replace the air bag diagnostic monitor when all wire repairs are complete. 3. If the diagnostic trouble code returns after making all wiring repairs, then replace the indicated component. Removal and Installation 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY POSITIVE CABLE MUST BE DISCONNECTED FOR ONE MINUTE PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 mites or more to relearn the strategy. 2. Locate air bag diagnostic monitor beneath and to the left of the steering column and disconnect the two connectors. 3. Depress tabs retaining air bag diagnostic monitor to air bag monitor bracket. Slide air bag diagnostic monitor off air bag monitor bracket. 4. Disconnect electrical wiring connectors to air bag diagnostic monitor. Remove air bag diagnostic monitor. 5. For installation, follow removal procedures in reverse order. Prove out system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Motor Relay <--> [Starter Relay] > Component Information > Locations Starter Motor Relay: Locations Engine Compartment View The Starter Motor Relay is located at the LH front corner of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation Power Control Module (PCM). Description The operation of the E4OD automatic transmission is controlled by the PCM. Many input sensors provide information to the PCM, which then controls the actuators which affect transmission operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Instrument Panel View The Wiper Control Module is located behind RH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 426 Wiper Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > Customer Interest for Anti-Theft Hood Switch: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: Customer Interest Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Anti-Theft Hood Switch: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: All Technical Service Bulletins Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > Customer Interest for Anti-Theft Hood Switch: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: Customer Interest Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Anti-Theft Hood Switch: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: All Technical Service Bulletins Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement Part Article No. 01-19-4 10/01/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES 1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 201000, 201200 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > With Power Windows Power Door Lock Switch: Diagrams With Power Windows Master Window/Door Lock Control Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > With Power Windows > Page 465 RH Power Door Lock/Window Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > With Power Windows > Page 466 Power Door Lock Switch: Diagrams Without Power Windows LH Power Door Lock Switch LH Power Door Lock Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > With Power Windows > Page 467 RH Power Door Lock Switch RH Power Door Lock Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > With Door Trim Power Mirror Switch (With Door Trim) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > With Door Trim > Page 472 Power Mirror Switch (Without Door Trim) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Driver's Seat Regulator Control Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Description and Operation Acceleration/Deceleration Sensor: Description and Operation PURPOSE This G-Switch is used to determine the vehicle's deceleration rate. OPERATION A component that is unique to the Ford light truck 4-Wheel ABS is the G-Switch, located where the Rear ABS valve used to be. The deceleration rate information, combined with signals from the wheel speed sensors, is used by the ECU to adjust ABS function to different operating conditions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Fluid Level Sensor, ABS Brake Fluid Level Sensor/Switch: Description and Operation Fluid Level Sensor, ABS Master Cylinder Reservoir PURPOSE The Master Cylinder Reservoir with Low Fluid Level Warning Switch monitors the fluid level in the master cylinder. OPERATION When a low fluid level condition occurs, a path to ground is provided through the dual brake warning switch to disable the Antilock brake system and illuminate the Antilock brake indicator. CONSTRUCTION The low fluid level warning switch is an integral part of the brake master cylinder reservoir. It is serviced as a part of the brake master cylinder reservoir. It consists of a float and magnet assembly and a reed switch. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Fluid Level Sensor, ABS > Page 484 Brake Fluid Level Sensor/Switch: Description and Operation Fluid Level Sensor, Brakes PURPOSE The brake fluid level switch closes with low brake fluid level. When closed, a ground is applied to the brake indicator and the lamp will illuminate. NOTE: The brake fluid level sensor is part of the master cylinder reservoir and is not serviced separately. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 485 Brake Fluid Level Sensor/Switch: Service and Repair The brake master cylinder sensor is part of the brake master cylinder reservoir and is not separately serviceable. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Service and Repair Braking Sensor/Switch: Service and Repair REMOVAL 1. Disconnect wiring harness connector from stoplight switch. 2. Remove self-locking pin and spacer from brake pedal pin. 3. Slide brake booster rod and stoplight switch off brake pedal pin. 4. Remove stoplight switch and bushing from brake booster rod. INSTALLATION 1. Position bushing in stoplight switch. 2. Position stoplight switch on brake booster rod, aligning holes. 3. Slide brake booster rod and stoplight switch onto brake pedal pin. 4. Install spacer and self-locking pin on brake pedal pin. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Vacuum Pump Switch, Brakes > Component Information > Locations Vacuum Hose Routing Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Vacuum Pump Switch, Brakes > Component Information > Locations > Page 492 Vacuum Pump Switch: Service and Repair Vacuum Hose Routing NOTE: The distributor modulator valve (low vacuum) switch is mounted to the left side fender panel. REMOVAL 1. Remove the negative battery cable from both batteries. 2. Disconnect vacuum hose and the electrical cable from distributor modulator valve switch. 3. Remove two attaching nuts and remove distributor modulator valve switch and A/C compressor mounting bracket (2882). INSTALLATION 1. Reverse the above procedure for installation, Tighten nuts to 8-11 Nm (6-8 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Wheel Speed Sensors Are Not Interchangeable Wheel Speed Sensor: Technical Service Bulletins ABS - Wheel Speed Sensors Are Not Interchangeable Article No. 98-5A-43 03/18/98 BRAKES - ANTI-LOCK BRAKE SYSTEM (ABS) - WHEEL SPEED SENSORS ARE NOT INTERCHANGEABLE LIGHT TRUCK: 1994-95 ECONOLINE ISSUE: The Anti-lock Brake System (ABS) wheel sensors are not interchangeable for 1994-95 Econolines. ACTION: If replacing an ABS wheel sensor, refer to the Econoline Wheel Speed Sensor Application Chart for proper wheel sensor usage. CAUTION: USING THE WRONG WHEEL SENSOR WILL NOT GIVE YOU ANY ERROR CODES, BUT THE WIRES WILL BE MISROUTED. THIS MAY EVENTUALLY CAUSE THE SENSOR WIRE TO CONTACT THE TIRE/WHEEL AND POTENTIALLY RUB THROUGH. PART NUMBER PART NAME F4UZ-2C204-C ABS Wheel Speed Sensor F4UZ-2C204-D ABS Wheel Speed Sensor F6UZ-2C204-AA ABS Wheel Speed Sensor F6UZ-2C204-AB ABS Wheel Speed Sensor OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-13-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensor: Locations Front The front brake antilock sensors are attached to the suspension knuckles, and the front brake antilock sensor indicators are pressed onto the backside of the rotor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front > Page 499 Wheel Speed Sensor: Locations Rear The Vehicle Speed Sensor (VSS) is located on the axle assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 500 Wheel Speed Sensor: Description and Operation PURPOSE A variable reluctance sensor and toothed speed indicator ring used to determine wheel speed. OPERATION As the ring teeth pass by the reluctance sensor, a pulsing voltage signal is generated and sent to the antilock brake system control module. Voltage pulses are directly proportional to rotational wheel speed. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Front REMOVAL 1. Raise vehicle on hoist. 2. Remove wheel and tire assembly. Rotor And Speed Sensor Ring 3. Remove caliper, rotor and hub assemblies. Speed Sensor Ring Removal 4. Using a 3-jaw puller, D80L-1013-A or equivalent, remove speed sensor ring from hub. CAUTION: Discard old speed sensor ring after removal. Do not reuse. INSTALLATION 1. Support center of hub so that wheel studs do not rest on work surface. CAUTION: When performing the following step, make sure indicator ring is pressed on straight. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 503 Front Speed Sensor Ring Installation 2. Position new speed sensor ring on hub. Using a cylinder with 98mm (3.9 inch) ID and 106mm (4.2 inch) OD, press the ring on to the hub. The ring must be fully seated against the shoulder in the hub. 3. Install hub, rotor and caliper assemblies. 4. Install wheel and tire assembly. Tighten wheel lugnuts to 115-142 Nm (85-105 ft lb). Rear INSPECTION 1. Remove the sensor. 2. View the speed sensor ring teeth through the sensor hole. Rotate the rear axle and check the speed sensor ring teeth for damage or breakage. Dented or broken teeth could cause the ABS system to function when not required. REMOVAL To service the speed sensor ring, the differential case must be removed from the axle housing, and the speed sensor ring pressed off the case. Upon removal, the speed sensor ring is to be discarded. It is not to be reused. Rear Antilock Brake System (RABS) INSPECTION 1. Remove the sensor. 2. View the speed sensor ring teeth through the sensor hole. Rotate the rear axle and check the speed sensor ring teeth for damage or breakage. Dented or broken teeth could cause the ABS system to function when not required. REMOVAL To service the speed sensor ring, the differential case must be removed from the axle housing, and the speed sensor ring pressed off the case. Upon removal, the speed sensor ring is to be discarded. It is not to be reused. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 504 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Rear Antilock Brake System Rear Speed Sensor REMOVAL 1. At the rear axle housing pull the wiring harness connector from the speed sensor. 2. Remove the speed sensor hold down bolt and remove the speed sensor from the rear axle housing. INSTALLATION 1. Clean the rear axle housing mounting surface. Use care to prevent dirt from entering the rear axle housing. 2. Inspect and clean the magnetized sensor pole piece to make sure that it is free from loose metal particles which could cause erratic system operation. Inspect the speed sensor O-ring for damage and replace if necessary. 3. Lightly lubricate the speed sensor O-ring with motor oil, align the bolt hole, and install. NOTE: Do not apply force to the plastic sensor connector. The sensor flange should slide to the mounting surface. This will make sure the air gap setting is between 0.127-1.143mm (0.005-0.045 in). 4. Install the speed sensor hold-down bolt and tighten to 34-40 Nm (25-29 ft lb). 5. Push the connector on the speed sensor. Front REMOVAL and INSTALLATION 1. From frame rail, disconnect sensor assembly two-pin connector from wiring harness. 2. Separate sensor cable from brake hose clips. 3. Remove sensor out of mating hole. 5. Remove the rotor. 5. For installation, follow removal procedures in reverse order. Tighten retaining bolt to 5-6 Nm (44-53 in lb). Rear REMOVAL Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 505 1. Pull the wiring harness connector from the sensor. 2. Remove the sensor hold down bolt and remove the sensor from the axle housing. INSTALLATION 1. Clean the axle mounting surface. Use care to prevent dirt from entering the axle housing. 2. Inspect and clean the magnetized sensor pole piece to make sure that it is free from loose metal particles which could cause erratic system operation. Replace the sensor O-ring. 3. Lightly lubricate the sensor O-ring with motor oil, align the sensor bolt hole, and install. Do not apply force to the plastic sensor connector. The sensor flange should slide to the mounting surface. This will make sure the air gap setting is between 0.127-1.14mm (0.005-0.045 in). 4. Install the hold down bolt and tighten to 34-40 Nm (25-30 ft lb). 5. Push the electrical connector on the sensor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation Engine Oil Temperature (EOT) Sensor: Description and Operation Engine Oil Temperature Sensor The Engine Oil Temperature (EOT) sensor changes resistance in response to changing temperature of the engine oil. The engine oil temperature sensor resistance decreases as the engine oil temperature increases providing a signal to the Powertrain Control Module (PCM), indicating the temperature of the engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation > Page 514 Engine Oil Temperature (EOT) Sensor: Service and Repair REMOVAL 1. Disconnect engine oil temperature sensor electrical connector. 2. Approximately 0.94 liters (one quart) of engine oil must be removed prior to sensor removal. Remove one quart of engine oil from high pressure oil pump reservoir using Rotunda Vacuum Tester 014-R1058 or equivalent. 3. Remove engine oil temperature sensor. INSTALLATION 1. Install engine oil temperature sensor. 2. Connect engine oil temperature sensor electrical connector. 3. Fill engine oil to proper level. 4. Refill oil pump reservoir with engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic Engine Coolant Temperature Sender: Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic > Page 519 6. In the Remarks Section, write "Returned per TSB 95-13-2". 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 FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Brake ON/OFF Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake ON/OFF Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls for Brake ON/OFF Switch: > NHTSA 06V286000 > Jul > 06 > Recall 06V286000: Cruise Control Switch Fire Hazard Brake ON/OFF Switch: Recalls Recall 06V286000: Cruise Control Switch Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/E450 1996-2002 Ford/Econoline 1994-1996 Ford/Excursion 2000-2002 Ford/Explorer 1998 Ford/F250 1994-2002 Ford/F350 1994-2002 Ford/F450 1994-2002 Ford/F550 1994-2002 Ford/Mountaineer 1998 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 06V286000 MFG'S REPORT DATE: July 27, 2006 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 1200000 SUMMARY: On certain trucks equipped with speed control, gasoline or natural gas engines, the speed control deactivation switch may overheat. CONSEQUENCE: Overheat could result in smoke, or burn and in an underhood fire. REMEDY: Dealers will install a fused wiring harness into the speed control system free of charge. The recall is expected to begin on August 7, 2006. Owners may contact Ford at 1-866-436-7332. NOTES: Ford recall No. 05S28. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake ON/OFF Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake ON/OFF Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake ON/OFF Switch: > NHTSA 06V286000 > Jul > 06 > Recall 06V286000: Cruise Control Switch Fire Hazard Brake ON/OFF Switch: All Technical Service Bulletins Recall 06V286000: Cruise Control Switch Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/E450 1996-2002 Ford/Econoline 1994-1996 Ford/Excursion 2000-2002 Ford/Explorer 1998 Ford/F250 1994-2002 Ford/F350 1994-2002 Ford/F450 1994-2002 Ford/F550 1994-2002 Ford/Mountaineer 1998 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 06V286000 MFG'S REPORT DATE: July 27, 2006 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 1200000 SUMMARY: On certain trucks equipped with speed control, gasoline or natural gas engines, the speed control deactivation switch may overheat. CONSEQUENCE: Overheat could result in smoke, or burn and in an underhood fire. REMEDY: Dealers will install a fused wiring harness into the speed control system free of charge. The recall is expected to begin on August 7, 2006. Owners may contact Ford at 1-866-436-7332. NOTES: Ford recall No. 05S28. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Page 542 Brake ON/OFF Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 551 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 552 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 553 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 554 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 555 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 556 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 557 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 558 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 559 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 560 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 561 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 562 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 563 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 564 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 565 Owner Letter Owner Letter not available at this time. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 571 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 572 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 573 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 574 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 575 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 576 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 577 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 578 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 579 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 580 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 581 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 582 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 583 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 584 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 585 Owner Letter Owner Letter not available at this time. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Page 586 Clutch Switch: Service and Repair 1. Disconnect deactivator switch electrical connector. 2. Unscrew switch to remove. 3. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 600 Cruise Control Switch: Service and Repair 1. Disable air bag system. 2. Remove four air bag module to steering wheel attaching nuts, then lift module rearward from steering wheel. 3. Disconnect air bag electrical connector from clockspring contact connector. 4. Remove air bag module from steering wheel. NOTE: Position air bag module on bench with trim cover facing upward. 5. Disconnect horn/speed control black wire harness connector from clockspring contact connector located in upper center of steering wheel. 6. Remove two steering column switch attaching screws. 7. Remove electrical tape from electrical connectors located at each upper clip in steering wheel. 8. Disconnect speed control switch wires at untapped wire connectors, then remove switches. 9. Reverse procedure to install. Torque air bag module to steering wheel nut and washer assemblies to 35-53 in lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams Auxiliary A/C-Heater Blower Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary Blower Motor Switch: Testing and Inspection Auxiliary Auxiliary A/C-Heater Blower Switch - Component Testing Procedure Auxiliary A/C-Heater Blower Switch - Terminal Locations Auxiliary A/C-Heater Blower Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary > Page 607 Blower Motor Switch: Testing and Inspection Front Blower Switch Front Blower Switch - Component Testing Procedure Front Blower Switch - Terminal Locations Front Blower Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary > Page 608 Blower Motor Switch: Testing and Inspection Rear Auxiliary Rear Auxiliary Blower Switch - Component Testing Procedure Rear Auxiliary Blower Switch - Terminal Locations Rear Auxiliary Blower Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Page 609 Blower Motor Switch: Service and Repair Rear Air Control Switch View REMOVAL AND INSTALLATION 1. Using a screwdriver, carefully pry the rear control assembly out of the headliner. 2. Disconnect the electrical connector from the heater blower motor switch (18578). 3. If necessary, remove the knob from the heater blower motor switch and remove the switch from the rear control unit. 4. For installation, follow removal steps in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Filter Restriction Sensor > Component Information > Description and Operation Fuel Filter Restriction Sensor: Description and Operation The 7.3L diesel engine is equipped with a fuel filter restriction sensor. A restriction indicator light is provided on the instrument panel (04320) to alert the operator. If the restriction indicator light goes on during normal operation, the fuel filter should be changed as soon as practical. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations Water In Fuel Sensor: Locations Engine View The Water In Fuel Sensor is located at the top LH side of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > With E4OD Transmission Backup Lamp Switch: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > With E4OD Transmission > Page 622 Backup Lamp Switch: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > With E4OD Transmission Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > With E4OD Transmission > Page 625 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 626 Backup Lamp Switch: Testing and Inspection Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake ON/OFF Switch <--> [Brake Light Switch] > Component Information > Diagrams Brake ON/OFF Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake ON/OFF Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 630 Brake ON/OFF Switch: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect battery ground cable. Fig. 3 Stop Light Switch Replacement 2. Lift locking tab, then disconnect electrical connector from switch. 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. NOTE: Ensure stop light switch wires are of sufficient length to allow full travel of the brake pedal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch (C217) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 634 Hazard Warning Switch: Testing and Inspection Multi-Function Switch - Component Testing Procedure Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 635 Wiper/Washer Switch - Terminal Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 636 Multi-Function Switch - Schematic - Dimmer, Flash-to-Pass, Turn/Hazard Portion Of Multi-Function Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 637 Hazard Warning Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Multi-Function Switch (C218) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 641 Headlamp Dimmer Switch: Testing and Inspection Multi-Function Switch - Component Testing Procedure Wiper/Washer Switch - Terminal Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 642 Multi-Function Switch - Schematic - Dimmer, Flash-to-Pass, Turn/Hazard Portion Of Multi-Function Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 643 Headlamp Dimmer Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Main Light Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 647 Main Light Switch: Testing and Inspection Main Light Switch - Component Testing Procedure Main Light Switch - Terminal Locations Main Light Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 648 Main Light Switch: Service and Repair REMOVAL AND INSTALLATION 1. Remove engine cover. 2. Remove ash tray retainer attaching screws, then remove retainer. 3. Remove steering column center and left snap molding. 4. Remove cigar lighter element. Headlamp Switch 5. Remove headlamp switch knob and shaft by inserting a hooked tool into knob slot to depress spring, Fig. 2. 6. Unscrew bezel from instrument panel finish panel. 7. Remove steering column opening cover attaching screws, then the cover. 8. Remove 6 screws and steering column lower reinforcement. 9. Remove instrument cluster finish panel attaching screws. 10. Pull finish panel rearward, unsnap panel retainers, then disconnect panel electrical connectors. 11. Remove headlamp control shaft by depressing release button on switch housing with shaft in full On position, then pull shaft from switch. 12. Remove switch attaching nut, remove switch, then disconnect switch electrical connector. 13. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch (C217) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 652 Turn Signal Switch: Testing and Inspection Multi-Function Switch - Component Testing Procedure Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 653 Wiper/Washer Switch - Terminal Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 654 Multi-Function Switch - Schematic - Dimmer, Flash-to-Pass, Turn/Hazard Portion Of Multi-Function Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 655 Turn Signal Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement Part Article No. 01-19-4 10/01/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES 1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 201000, 201200 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Engine Control - Poor Acceleration Response Accelerator Pedal Position Sensor: Technical Service Bulletins Engine Control - Poor Acceleration Response Article No. 03-21-6 10/06/03 DRIVEABILITY - ACCELERATOR PEDAL - LACK OF ACCELERATOR CONTROL WHEN MOVING FROM IDLE POSITION - POOR OR NO ENGINE RESPONSE - 7.3L DIT FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 95-10-10 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A lack of accelerator control when moving off of the idle position may occur on some vehicles. The vehicle's engine will be at idle RPM only. This may be caused by the Idle Validation Switch (IVS) contacts not properly closing due to interference of contacts with the switch housing. ACTION Remove and install a revised accelerator pedal assembly which includes IVS. Refer to the appropriate year 7.3L Turbo Diesel Service Manual Supplement, Pages 10-02-2 and 10-02-3, for service procedures. NOTE THE IVS DATE OF MANUFACTURE IS STAMPED NEAR ITS CONNECTOR MATING SURFACE. THE DATE CODE READS AS FOLLOWS: TWO (2) DIGITS FOR CALENDAR YEAR, FOLLOWED BY TWO (2) DIGITS FOR WEEK OF CALENDAR YEAR WHEN MANUFACTURED. FOR EXAMPLE: 9503 INDICATES SWITCH MADE THE THIRD WEEK OF 1995. NOTE ALL SWITCHES WITH A DATE CODE OF 9510 AND LATER HAVE THE CORRECTED SWITCH HOUSING. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-10-10 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 666 Accelerator Pedal Position Sensor: Specifications Accelerator Pedal Position Sensor 22-28 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 667 Accelerator Pedal Position Sensor: Locations Full Body View (Part 3 Of 3) The Accelerator Pedal Position Sensor is located behind LH side of instrument panel, above accelerator pedal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor: Description and Operation Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor The Accelerator Pedal (AP) position sensor is a potentiometer that provides a signal to the Powertrain Control Module (PCM) proportional to the accelerator pedal position. The AP position sensor connects to the accelerator pedal shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor > Page 670 Accelerator Pedal Position Sensor: Description and Operation Idle Validation Switch The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 671 Accelerator Pedal Position Sensor: Adjustments The Accelerator Pedal (AP) position sensor cannot be adjusted. If service is required, replace accelerator pedal and shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 672 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor CAUTION: The accelerator pedal assembly is a calibrated unit and must be handled with care. REMOVAL 1. Disconnect the electrical connectors from the Idle Validation Switch (IVS) and the Accelerator Pedal Position (AP) sensor. 2. remove the bolts holding the accelerator pedal and shaft to the instrument panel, 3. Remove the accelerator pedal and sensor assembly from the instrument panel. INSTALLATION 1. Position accelerator pedal and sensor assembly to instrument panel and install lower nut hand tight. 2. Install and tighten accelerator pedal and sensor assembly nuts to 22-28 Nm (17-20 ft lb). 3. Connect the electrical connectors to the IVS and AP sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow Sensor: Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement > Page 677 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 Full Body View (Part 3 Of 3) The Barometric Pressure Sensor is located behind the LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 681 Barometric Pressure Sensor: Description and Operation Barometric Pressure Sensor The Barometric Pressure (BARO) sensor is a variable capacitance sensor that, when supplied with a 5-volt reference signal from the Powertrain Control Module (PCM), produces an analog voltage that indicates barometric pressure. The sensor signal is used to determine altitude to adjust timing and quantity of fuel to optimize engine operation. The output of the barometric pressure sensor is one of the variables used to calculate glow plug on time. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 682 Barometric Pressure Sensor: Service and Repair Barometric Pressure Sensor REMOVAL 1. Disconnect Barometric Pressure (BARO) sensor electrical connector. 2. Remove BARO sensor. INSTALLATION 1. Install BARO sensor. 2. Connect sensor electrical connector Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: Customer Interest Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 691 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 697 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Camshaft Position Sensor: > 03-21-14 > Oct > 03 > Drive Belts - Belt Shreds and/or Comes Off Drive Belt: All Technical Service Bulletins Drive Belts - Belt Shreds and/or Comes Off Article No. 03-21-14 10/06/03 FEAD BELT - WEARS, SHREDS, AND/OR COMES OFF - VEHICLES WITH 7.3L DIT ENGINE AND 130 AMP ALTERNATOR BUILT 8/94 THROUGH 5/96 FORD: 1995-1996 E-350, F SUPER DUTY, F-250, F-350 Article 96-17-19 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet, and to update part information and vehicle criteria. ISSUE The Front End Accessory Drive (FEAD) belt may wear, shred and/or come off during deceleration. ACTION Replace the belt tensioner and the FEAD belt. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect the belt for rear edge belt wear and move the tensioner arm to see if it can be cocked out of position. 2. Check for a sticking or binding tensioner by moving the tensioner through its full travel. 3. If any of these conditions exist, replace the belt tensioner following the procedure outlined in the appropriate model/year Service Manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-17-19 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 708 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located at the front of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 709 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor is a Hall effect sensor that generates a digital frequency while windows in a target wheel pass through its magnetic field. The frequency of the windows passing by the sensor, as well as the width of selected windows, allows the Powertrain Control Module (PCM) to detect engine speed and position. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 710 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect Camshaft Position (CMP) sensor electrical connector. 2. Remove bolt and CMP sensor. INSTALLATION 1. Install CMP sensor and bolt. 2. Connect CMP sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation Cylinder Identification Sensor: Description and Operation PURPOSE The Cylinder Identification (CID) circuit output provides information to the Injector Driver Module (IDM) on the position of each cylinder's TDC position. so that current can be applied to the correct injector at the proper time. OPERATION The CID is one of two digital control signals used by the IDM. The CID is produced in the Powertrain Control Module (PCM) and sent to the IDM via the CID circuit. The CID provides synchronization information to the engine's first and fifth injector in the firing order. The IDM then uses this information to properly control injector operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation Engine Oil Temperature (EOT) Sensor: Description and Operation Engine Oil Temperature Sensor The Engine Oil Temperature (EOT) sensor changes resistance in response to changing temperature of the engine oil. The engine oil temperature sensor resistance decreases as the engine oil temperature increases providing a signal to the Powertrain Control Module (PCM), indicating the temperature of the engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation > Page 717 Engine Oil Temperature (EOT) Sensor: Service and Repair REMOVAL 1. Disconnect engine oil temperature sensor electrical connector. 2. Approximately 0.94 liters (one quart) of engine oil must be removed prior to sensor removal. Remove one quart of engine oil from high pressure oil pump reservoir using Rotunda Vacuum Tester 014-R1058 or equivalent. 3. Remove engine oil temperature sensor. INSTALLATION 1. Install engine oil temperature sensor. 2. Connect engine oil temperature sensor electrical connector. 3. Fill engine oil to proper level. 4. Refill oil pump reservoir with engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Air Temperature Sensor 16-24 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 721 Intake Air Temperature Sensor: Locations Engine Compartment View The Intake Air Temperature Sensor is located at the center of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 722 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor The Intake Air Temperature (IAT) sensor changes resistance in response to changing intake air temperature. The IAT sensor resistance decreases as the air temperature increases, providing a signal to the Powertrain Control Module (PCM) indicating temperature of the incoming intake air. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 723 Intake Air Temperature Sensor: Service and Repair Intake Air Temperature Sensor REMOVAL 1. Disconnect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect wire harness from Intake Air Temperature (IAT) sensor. 3. Remove IAT sensor from air cleaner housing. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten intake air temperature sensor to 16-24 Nm (12-15 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations Manifold Absolute Pressure Sensor: Locations Engine Compartment View The Manifold Absolute Pressure Sensor is located at the right side of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 727 Manifold Absolute Pressure Sensor: Description and Operation Manifold Absolute Pressure Sensor The Manifold Absolute Pressure (MAP) sensor is used on some applications. The MAP sensor measures the pressure in the intake manifold and provides this information as a variable frequency signal to the Powertrain Control Module (PCM). With the Ignition Switch in the Key ON/Engine OFF position, the MAP sensor will indicate the barometric pressure in the intake manifold. The MAP sensor is used to indicate boost pressure on the diesel engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 728 Manifold Absolute Pressure Sensor: Service and Repair Manifold Absolute Pressure Sensor REMOVAL 1 Disconnect battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect vacuum hose from Manifold Absolute Pressure (MAP) sensor. 3. Remove fasteners attaching MAP sensor and bracket assembly below cowl drip rail. INSTALLATION Follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 733 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 734 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 735 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 736 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 737 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 738 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 739 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 740 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 741 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 742 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 743 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 744 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 745 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 746 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 747 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Exhaust Back Pressure Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 752 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations Behind Instrument Panel Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations > Page 756 Throttle Full Close Switch: Description and Operation The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations > Page 757 Throttle Full Close Switch: Service and Repair Removal 1. Disconnect the electrical connectors from the idle validation switch and the accelerator pedal position sensor. 2. Remove the nuts holding the accelerator pedal and sensor assembly to the instrument panel. 3. Remove the accelerator pedal and sensor assembly from the instrument panel. Installation 1. Position accelerator pedal and sensor assembly to instrument panel and install accelerator pedal and sensor assembly lower nut hand tight. 2. Install and tighten the accelerator pedal and sensor assembly nuts to 21-29 nm (15-21 lb-ft). 3. Connect the electrical connectors to the idle validation switch and the accelerator pedal position sensor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations > Page 758 Accelerator Pedal Sensors Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: Customer Interest A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission Transmission Position Switch/Sensor: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission > Page 774 Transmission Position Switch/Sensor: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only > Page 777 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission Transmission Position Switch/Sensor: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission > Page 780 Transmission Position Switch/Sensor: Testing and Inspection With 4R70W Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 785 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 786 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 787 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 788 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 789 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 790 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 791 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 792 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor The Vehicle Speed Sensor (VSS) is mounted on the front of the rear axle housing above the pinion flange. The speed sensor ring is located in the rear axle between the ring gear and differential case. The signal from the sensor is not routed directly to the Powertrain Control Module (PCM). It is received by the Programmable Speedometer/Odometer Module (PSOM), which provides the PCM with a vehicle speed signal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 793 Vehicle Speed Sensor: Testing and Inspection Vehicle Speed Sensor Schematic DESCRIPTION The Vehicle Speed Sensor (VSS) is a variable reluctance sensor that generates a waveform with a frequency that is proportional to vehicle speed. When the vehicle is moving slowly, the sensor produces a low frequency signal. As the vehicle speed increases, the sensor produces a higher frequency signal. The Powertrain Control Module (PCM) uses this signal to control fuel injection, ignition timing and transmission/transaxle shift points. This Pinpoint Test is intended to diagnose only the following: VSS Harness Circuits - Vehicle Speed Sensor - PCM Test DP1 - Continuous Code 29/452: Complete VSS Drive Cycle Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 794 Test DP2,3 and 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Exhaust Back Pressure Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 800 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Engine Control - Poor Acceleration Response Accelerator Pedal Position Sensor: Technical Service Bulletins Engine Control - Poor Acceleration Response Article No. 03-21-6 10/06/03 DRIVEABILITY - ACCELERATOR PEDAL - LACK OF ACCELERATOR CONTROL WHEN MOVING FROM IDLE POSITION - POOR OR NO ENGINE RESPONSE - 7.3L DIT FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 95-10-10 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A lack of accelerator control when moving off of the idle position may occur on some vehicles. The vehicle's engine will be at idle RPM only. This may be caused by the Idle Validation Switch (IVS) contacts not properly closing due to interference of contacts with the switch housing. ACTION Remove and install a revised accelerator pedal assembly which includes IVS. Refer to the appropriate year 7.3L Turbo Diesel Service Manual Supplement, Pages 10-02-2 and 10-02-3, for service procedures. NOTE THE IVS DATE OF MANUFACTURE IS STAMPED NEAR ITS CONNECTOR MATING SURFACE. THE DATE CODE READS AS FOLLOWS: TWO (2) DIGITS FOR CALENDAR YEAR, FOLLOWED BY TWO (2) DIGITS FOR WEEK OF CALENDAR YEAR WHEN MANUFACTURED. FOR EXAMPLE: 9503 INDICATES SWITCH MADE THE THIRD WEEK OF 1995. NOTE ALL SWITCHES WITH A DATE CODE OF 9510 AND LATER HAVE THE CORRECTED SWITCH HOUSING. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-10-10 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 806 Accelerator Pedal Position Sensor: Specifications Accelerator Pedal Position Sensor 22-28 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 807 Accelerator Pedal Position Sensor: Locations Full Body View (Part 3 Of 3) The Accelerator Pedal Position Sensor is located behind LH side of instrument panel, above accelerator pedal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor: Description and Operation Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor The Accelerator Pedal (AP) position sensor is a potentiometer that provides a signal to the Powertrain Control Module (PCM) proportional to the accelerator pedal position. The AP position sensor connects to the accelerator pedal shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor > Page 810 Accelerator Pedal Position Sensor: Description and Operation Idle Validation Switch The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 811 Accelerator Pedal Position Sensor: Adjustments The Accelerator Pedal (AP) position sensor cannot be adjusted. If service is required, replace accelerator pedal and shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 812 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor CAUTION: The accelerator pedal assembly is a calibrated unit and must be handled with care. REMOVAL 1. Disconnect the electrical connectors from the Idle Validation Switch (IVS) and the Accelerator Pedal Position (AP) sensor. 2. remove the bolts holding the accelerator pedal and shaft to the instrument panel, 3. Remove the accelerator pedal and sensor assembly from the instrument panel. INSTALLATION 1. Position accelerator pedal and sensor assembly to instrument panel and install lower nut hand tight. 2. Install and tighten accelerator pedal and sensor assembly nuts to 22-28 Nm (17-20 ft lb). 3. Connect the electrical connectors to the IVS and AP sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow Sensor: Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement > Page 817 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Filter Restriction Sensor > Component Information > Description and Operation Fuel Filter Restriction Sensor: Description and Operation The 7.3L diesel engine is equipped with a fuel filter restriction sensor. A restriction indicator light is provided on the instrument panel (04320) to alert the operator. If the restriction indicator light goes on during normal operation, the fuel filter should be changed as soon as practical. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Injection Control Pressure Sensor (ICP) <--> [Fuel Pressure Sensor/Switch] > Component Information > Locations Injection Control Pressure Sensor (ICP): Locations Sensor And Actuator Locations The Injection Control Pressure (ICP) is located in the cylinder head oil gallery. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Injection Control Pressure Sensor (ICP) <--> [Fuel Pressure Sensor/Switch] > Component Information > Locations > Page 824 Injection Control Pressure Sensor (ICP): Description and Operation Injection Control Pressure Sensor The Injection Control Pressure (ICP) sensor is a variable capacitance sensor that, when supplied with a 5-volt reference signal from the Powertrain Control Module (PCM), produces a linear analog voltage signal that indicates oil pressure. The ICP sensor provides a feedback signal to indicate high pressure oil so that the PCM can command the correct injector timing, pulse width and injection control pressure for proper fuel delivery at all speed and load conditions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Injection Control Pressure Sensor (ICP) <--> [Fuel Pressure Sensor/Switch] > Component Information > Locations > Page 825 Injection Control Pressure Sensor (ICP): Service and Repair Injection Control Pressure Sensor REMOVAL 1. Disconnect Injection Control Pressure (ICP) sensor electrical connector. 2. Remove ICP sensor. INSTALLATION 1. Install ICP sensor. 2. Connect sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations Behind Instrument Panel Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations > Page 829 Throttle Full Close Switch: Description and Operation The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations > Page 830 Throttle Full Close Switch: Service and Repair Removal 1. Disconnect the electrical connectors from the idle validation switch and the accelerator pedal position sensor. 2. Remove the nuts holding the accelerator pedal and sensor assembly to the instrument panel. 3. Remove the accelerator pedal and sensor assembly from the instrument panel. Installation 1. Position accelerator pedal and sensor assembly to instrument panel and install accelerator pedal and sensor assembly lower nut hand tight. 2. Install and tighten the accelerator pedal and sensor assembly nuts to 21-29 nm (15-21 lb-ft). 3. Connect the electrical connectors to the idle validation switch and the accelerator pedal position sensor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations > Page 831 Accelerator Pedal Sensors Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: Customer Interest Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 841 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 847 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 848 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located at the front of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 849 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor is a Hall effect sensor that generates a digital frequency while windows in a target wheel pass through its magnetic field. The frequency of the windows passing by the sensor, as well as the width of selected windows, allows the Powertrain Control Module (PCM) to detect engine speed and position. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 850 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect Camshaft Position (CMP) sensor electrical connector. 2. Remove bolt and CMP sensor. INSTALLATION 1. Install CMP sensor and bolt. 2. Connect CMP sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams Ignition Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 854 Ignition Switch: Testing and Inspection Ignition Switch - Component Testing Procedure (Part 1 Of 2) Ignition Switch - Component Testing Procedure (Part 2 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 855 Ignition Switch - Terminal Locations Ignition Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Center Air Bag Primary Crash Sensor-to-Radiator Support Screws ...................................................................................................10-14 Nm (7-10 Lb-Ft) Front Air Bag Primary Crash Sensor-to-Right Frame Screws ...........................................................................................................13-17 Nm (10-13 Lb-Ft) Replacement Retaining Screws .......................................................................................................... ...............................................13-17 Nm (10-13 Lb-Ft) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Radiator Center Forward Primary Crash Sensor Impact Sensor: Locations Radiator Center Forward Primary Crash Sensor Engine Compartment View The Radiator Center Forward Primary Crash Sensor is located at the lower center front of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Radiator Center Forward Primary Crash Sensor > Page 862 Impact Sensor: Locations Right Frame Rail Primary Crash Sensor Full Body View (Part 2 Of 2) The Right Frame Rail Primary Crash Sensor is mounted on the RH side frame rail. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 863 RH Kick Panel Safing Sensor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 864 Impact Sensor: Description and Operation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH A SUPPLEMENTAL AIR BAG RESTRAINT SYSTEM HAS BEEN INVOLVED IN A CRASH WHERE THE RADIATOR SUPPORT, FRAME RAILS OR COWLS HAVE BEEN DAMAGED, INSPECT THE SENSOR MOUNTING BRACKETS FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. IN ADDITION, MAKE SURE THE BODY STRUCTURE IN THE AREA OF THE SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: Undamaged sensors will reset automatically after an accident and can be reused. The sensors are electrical switches which react to impacts according to direction and force. Sensors discriminate between impacts that require air bag inflation and impacts that do not require air bag inflation. When an impact occurs that requires air bag inflation, the sensor contacts close, completing the electrical circuit necessary for system operation. Three sensors are mounted in the vehicle. Their locations are as follows: - A primary air bag sensor at the center of the radiator support. - A primary sensor on the right frame rail. - A safing sensor at the right cowl side trim panel. At least two sensors (one primary sensor and one safing sensor) must be closed to inflate the air bag. The sensors automatically "reset" after a collision and do not need to be replaced unless they are physically damaged. Replace only if proper alignment is not possible due to bent brackets, cut wires, smashed connectors, etc. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Center Primary Crash Sensor and Bracket Impact Sensor: Service and Repair Center Primary Crash Sensor and Bracket Removal 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE POSITIVE BATTERY CABLE MUST BE DISCONNECTED PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. NOTE: To service stripped center air bag primary crash sensor and bracket retaining screws, replace screws with N808545. Tighten to 13-17 Nm (10-13 lb-ft). - When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect sensor wiring connector from wiring assembly connector. 3. Remove two screws retaining center radiator sensor. Remove sensor. Installation 1. Position sensor to radiator support. 2. Secure sensor with two retaining screws. Tighten to 10-14 Nm (7.5-10 lb-ft). 3. Connect sensor wiring connector to wiring assembly connector and secure wiring retainer. 4. Connect battery positive cable. 5. verify air bag indicator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Center Primary Crash Sensor and Bracket > Page 867 Impact Sensor: Service and Repair Right Rear (Frame) Primary Crash Sensor and Bracket Removal 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY POSITIVE CABLE MUST BE DISCONNECTED PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. NOTE: To service stripped frame air bag sensor and bracket retaining screws, replace screws with 13 mm screw. Tighten to 13-17 Nm (10-13 lb-ft). - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect sensor wiring connector from wiring assembly connector. 3. Remove two screws retaining primary sensor to the RH frame rail. Installation 1. Position sensor to RH frame rail. 2. Secure sensor with two screws. Tighten screws to 13-17 Nm (10-13 lb-ft). 3. Connect sensor wiring connector to wiring assembly connector and secure with retainer. 4. Connect battery positive cable. 5. Verify air bag indicator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Specifications Safing Sensor: Specifications Front Air Bag Safing Sensor-to-Right Cowl Side Panel Screws .........................................................................................................8-10 Nm (71-89 Lb-In) Replacement Retaining Screws .......................................................................................................... ...............................................13-17 Nm (10-13 Lb-Ft) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Specifications > Page 871 Safing Sensor: Locations Full Body View (Part 2 Of 2) The RH Kick Panel Safing Sensor is mounted near RH cowl panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Specifications > Page 872 Safing Sensor: Description and Operation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH A SUPPLEMENTAL AIR BAG RESTRAINT SYSTEM HAS BEEN INVOLVED IN A CRASH WHERE THE RADIATOR SUPPORT, FRAME RAILS OR COWLS HAVE BEEN DAMAGED, INSPECT THE SENSOR MOUNTING BRACKETS FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. IN ADDITION, MAKE SURE THE BODY STRUCTURE IN THE AREA OF THE SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: Undamaged sensors will reset automatically after an accident and can be reused. The sensors are electrical switches which react to impacts according to direction and force. Sensors discriminate between impacts that require air bag inflation and impacts that do not require air bag inflation. When an impact occurs that requires air bag inflation, the sensor contacts close, completing the electrical circuit necessary for system operation. Three sensors are mounted in the vehicle. Their locations are as follows: - A primary air bag sensor at the center of the radiator support. - A primary sensor on the right frame rail. - A safing sensor at the right cowl side trim panel. At least two sensors (one primary sensor and one safing sensor) must be closed to inflate the air bag. The sensors automatically "reset" after a collision and do not need to be replaced unless they are physically damaged. Replace only if proper alignment is not possible due to bent brackets, cut wires, smashed connectors, etc. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Specifications > Page 873 Safing Sensor: Service and Repair Removal 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY POSITIVE CABLE MUST BE DISCONNECTED FOR ONE MINUTE PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. NOTE: - To service stripped retaining screws, replace old screws with N808545. Tighten to 13-17 Nm (9-13 lb-ft). - When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Remove RH cowl side panel. 3. Disconnect sensor wiring connector from wiring assembly connector. 4. Remove two screws retaining cowl side panel. Remove sensor. Installation 1. Position sensor to cowl side panel. 2. Secure sensor with two retaining screws. Tighten to 8-10 Nm (71-89 lb-in). 3. Connect sensor wiring connector to wiring assembly connector. 4. Install RH cowl side panel. 5. Connect battery positive cable. 6. Verify air bag indicator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams Ignition Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 878 Ignition Switch: Testing and Inspection Ignition Switch - Component Testing Procedure (Part 1 Of 2) Ignition Switch - Component Testing Procedure (Part 2 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 879 Ignition Switch - Terminal Locations Ignition Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > With E4OD Transmission Neutral Safety Switch: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > With E4OD Transmission > Page 884 Neutral Safety Switch: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Park/Neutral Position Switch Park/Neutral Position Switch (With C6 Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Park/Neutral Position Switch > Page 887 Neutral Safety Switch: Diagrams Transmission Range Sensor Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Park/Neutral Position Switch > Page 888 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Testing and Inspection > With E4OD Transmission Neutral Safety Switch: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Testing and Inspection > With E4OD Transmission > Page 891 Neutral Safety Switch: Testing and Inspection With 4R70W Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > E4OD Transmission Neutral Safety Switch: Service and Repair E4OD Transmission REMOVAL AND INSTALLATION 1. Apply parking brake, then place gear selector lever in Neutral position. 2. Ensure transmission shift cable is correctly adjusted, then loosen Park/Neutral position switch retaining bolts. 3. Insert Gear Position Sensor Adjuster tool No. T92P-70010-AH, or equivalent, on Park/Neutral position switch into the three slots provided on the switch actuator and terminal plate. 4. Leaving the alignment tool in place, torque switch retaining bolts to 6 ft lb. 5. Remove alignment tool, adjustment can be verified visually by making sure the line etched in the housing are in a straight line when the Park/Neutral position switch is centered in neutral. 6. Check the operation of the Park/Neutral position switch. The back-up lamps should operate only with the transmission selector lever in reverse. The vehicle should only start with the selector lever in park or neutral. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > E4OD Transmission > Page 894 Neutral Safety Switch: Service and Repair C-6 Transmission REMOVAL AND INSTALLATION 1. Apply parking brake, then place gear selector lever in Neutral position. 2. Ensure transmission shift cable is correctly adjusted, then loosen Park/Neutral position switch retaining bolts. 3. Insert Gear Position Sensor Adjuster tool No. T91P-70010-A, or equivalent, on Park/Neutral position switch into the three slots provided on the switch actuator and terminal plate. 4. Leaving the alignment tool in place, torque switch retaining bolts to 6 ft lb. 5. Remove alignment tool, adjustment can be verified visually by making sure the line etched in the housing are in a straight line when the Park/Neutral position switch is centered in neutral. 6. Check the operation of the Park/Neutral position switch. The back-up lamps should operate only with the transmission selector lever in reverse. The vehicle should only start with the selector lever in park or neutral. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation Brake Switch - TCC: Description and Operation Brake On/Off (BOO) Switch DESCRIPTION The Brake On/0ff switch tells the powertrain control module when the brakes are applied. The switch is closed when the brakes are applied and open when they are released. FUNCTION Disengages torque converter clutch when brake is applied. RELATED SYMPTOMS Failed on or not connected - Torque converter clutch will not engage at less than 1/3 throttle. Failed off - Torque converter clutch will not disengage when brake is applied. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Description and Operation > Accelerator Pedal (AP) Sensor Throttle Position Sensor/Switch: Description and Operation Accelerator Pedal (AP) Sensor Accelerator Pedal (AP) Sensor DESCRIPTION The Accelerator Pedal (AP) Sensor is mounted on the accelerator pedal and detects the position of the accelerator pedal. OPERATION The accelerator pedal position information is sent as a voltage signal to the PCM. The PCM uses this information to determine shift scheduling and electronic pressure control. FUNCTION If a malfunction occurs in the AP sensor circuit, the PCM will recognize that the AP signal is out of specification. The PCM will then operate the E4OD at a high line pressure to prevent transmission damage. This higher line pressure results in harsh upshifts and engagements. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Description and Operation > Accelerator Pedal (AP) Sensor > Page 904 Throttle Position Sensor/Switch: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor Description The Throttle Position (TP) sensor is a potentiometer attached to the fuel injection pump and is operated by the throttle lever. Operation The TP sensor is incorporated to provide an electrical signal, which is proportional to the amount of fuel being delivered, as an input to the Powertrain Control Module (PCM). Based on this information, the TP sensor provides the proper shift scheduling and torque capacity. Should a malfunction occur in the TP sensor circuit, the electrical signal sent to the PCM will be recognized as erroneous. When this out-of-specification signal is detected, the PCM will operate the E4OD at a higher line pressure to protect the transmission from potential damage. This high line pressure, results in harsh upshifts and engagements. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power/Economy Mode Switch, A/T Transmission Mode Switch: Description and Operation Power/Economy Mode Switch, A/T Transmission Control Switch (TCS) DESCRIPTION The Transmission Control Switch (TCS) is a momentary contact switch which disables 4th gear operation and enables engine braking when activated. OPERATION When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM). The PCM then energizes the Transmission Control Indicator Lamp (TCIL) and the Coast Clutch Solenoid (CCS), applying the coast clutch to provide engine braking and cancels fourth gear operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power/Economy Mode Switch, A/T > Page 909 Transmission Mode Switch: Description and Operation Transmission Mode Switch Transmission Control Switch (TCS) DESCRIPTION The Transmission Control Switch (TCS) is a momentary contact switch which disables 4th gear operation and enables engine braking when activated. OPERATION When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM). The PCM then energizes the Transmission Control Indicator Lamp (TCIL) and the Coast Clutch Solenoid (CCS), applying the coast clutch to provide engine braking and cancels fourth gear operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: Customer Interest A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission Transmission Position Switch/Sensor: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission > Page 925 Transmission Position Switch/Sensor: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only > Page 928 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission Transmission Position Switch/Sensor: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission > Page 931 Transmission Position Switch/Sensor: Testing and Inspection With 4R70W Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Output Shaft Speed Sensor <--> [Transmission Speed Sensor, A/T] > Component Information > Locations Output Shaft Speed Sensor: Locations The Output Shaft Speed Sensor is located at the LH rear of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor PURPOSE Used as an input to determine shift schedule and Electronic Pressure Control (EPC) for temperature effects. DESCRIPTION The Transmission Fluid Temperature (TFT) sensor is a temperature-sensitive device called a thermistor it is located in the solenoid body assembly it sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with the transmission fluid temperature. OPERATION The PCM uses the voltage signal to determine whether a cold start shift schedule is necessary. The cold start shift schedule lowers shift speeds to allow for the reduced performance of cold engine operation. The TFT is part of the transmission solenoid assembly and is not replaced separately. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > With Power Door Locks Power Window Switch: Diagrams With Power Door Locks Master Window/Door Lock Control Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > With Power Door Locks > Page 943 RH Power Door Lock/Window Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > With Power Door Locks > Page 944 Power Window Switch: Diagrams Without Power Door Locks LH Power Window Switch RH Power Window Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Multi-Function Switch (C218) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 949 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch - Component Testing Procedure Wiper/Washer Switch - Terminal Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 950 Wiper/Washer Switch - Schematic - Wiper/Washer Portion Of Multi-Function Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 951 Windshield Washer Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi-Function Switch (C218) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 955 Wiper Switch: Testing and Inspection Refer to images for windshield wiper switch continuity test. Testing should be performed with a suitable ohmmeter. Fig. 35 Windshield Wiper Switch Connector Terminal Indentification. Fig. 36 Windshield Wiper Switch Continuity Test. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 956 Fig. 37 Windshield Wiper Switch Continuity Test (Part 1 Of 2). Fig. 37 Windshield Wiper Switch Continuity Test (Part 2 Of 2). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 957 Wiper Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. Torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' Alignment: Customer Interest Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 967 Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 968 (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 969 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 970 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' Alignment: All Technical Service Bulletins Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 976 Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 977 (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 978 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 979 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 984 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 985 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 986 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 987 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 988 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 989 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 990 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 991 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 992 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 993 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 994 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 995 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 996 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 997 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 998 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 999 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1000 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1001 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1002 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1003 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1004 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1005 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1006 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1007 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1008 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1009 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1010 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1011 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1012 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1013 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1014 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1015 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1016 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1017 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1018 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1019 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1020 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1021 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1022 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1023 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1024 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1025 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1026 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1027 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1028 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1029 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1030 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1031 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1032 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1033 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1034 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1035 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1036 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1037 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1038 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1039 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1040 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1041 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1042 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1043 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1044 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1045 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1046 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1047 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1048 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1049 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1050 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1051 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1052 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1053 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1054 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1055 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1056 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1057 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1058 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1059 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1060 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1061 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1062 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1063 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1064 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1065 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1066 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1067 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1068 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1069 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1070 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1071 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1072 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1073 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1074 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1075 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1076 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1077 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1078 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1084 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1085 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1086 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1087 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1088 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1089 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1090 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1091 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1092 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1093 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1094 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1095 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1096 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1097 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1098 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1099 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1100 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1101 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1102 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1103 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1104 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1105 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1106 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1107 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1108 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1109 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1110 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1111 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1112 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1113 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1114 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1115 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1116 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1117 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1118 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1119 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1120 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1121 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1122 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1123 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1124 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1125 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1126 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1127 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1128 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1129 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1130 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1131 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1132 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1133 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1134 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1135 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1136 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1137 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1138 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1139 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1140 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1141 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1142 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1143 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1144 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1145 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1146 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1147 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1148 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1149 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1150 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1151 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1152 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1153 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1154 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1155 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1156 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1157 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1158 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1159 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1160 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1161 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1162 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1163 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1164 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1165 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1166 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1167 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1168 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1169 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1170 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1171 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1172 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1173 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1174 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1175 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1176 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1177 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1178 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1179 Alignment: By Symptom Technical Service Bulletin # 02-16-8 Date: 020819 Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1180 front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1181 (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1182 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1183 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Technical Service Bulletin # 02-16-8 Date: 020819 Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1184 First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1185 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1186 (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1187 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 1188 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1189 Alignment: Specifications Caster .................................................................................................................................................. ............................................................. +2.0° to +7.5° Camber ................................................................................................................................................ ................................................................. 0° to +1.0° Toe-In, Inch ......................................................................................................................................... ......................................................... -0.19° to +0.31° Ball Joint Wear .................................................................................................................................... ....................................................... 1/32 in to +7.5 in Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber Alignment: Service and Repair Caster and Camber Fig. 4 Removing Caster/Camber Adjustment Sleeve Fig. 5 Caster/Camber Adjustment Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1192 Fig. 4 Caster/Camber Variation Chart Caster and camber adjustment is possible with adjusters available in 1/2 degree, 1 degree and 1 1/2 degree increments. One adjuster is used to adjust both caster and camber. Refer to Figs. 2 and 3 for adjuster replacement, then to Fig. 4 for adjuster variations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1193 Alignment: Service and Repair Ride Height 1. Prior to checking caster and camber, ensure vehicle front ride height is within 1/8 inch side to side. Fig. 1 Measuring Ride Height a. If the vehicle ride heights are not within specifications, redistribute load on loaded vehicles or slightly load empty vehicles on one side. b. If the ride heights cannot be brought within specifications, verify correct spring installation. c. The ride height variations stated are for checking purposes only. The vehicle does not have to operate within these specifications. d. 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. 2. If all the above checks have been made, check wheel alignment with suitable alignment equipment. 3. Using the ride heights obtained earlier, compare caster and camber readings to those listed in the Wheel Alignment Specifications. 4. If the caster and camber angles exceed the specifications, inspect front end for damaged suspension components. Replace as necessary. NOTE: Alignment equipment indicates a true reading only when the vehicle's frame is horizontal. Therefore, if the frame is not level (due to tire, spring or load differences), the caster angle reading must be modified to compensate for the frame angles. If the front is higher than the rear, subtract the amount of angle from the reading. If the front is lower than the rear, add the angle. To check frame angle, use a spirit protractor, and take the frame angle measurement on the lower frame flange at the flat area immediately adjacent to the rear spring front hanger. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Fuel Pressure Regulator The fuel pressure test port is a Schrader valve mounted on the fuel pressure regulator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments Idle Speed: Adjustments Engine idle speed and injection timing are controlled by the Powertrain Control Module (PCM) and are not adjustable. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Tag, disconnect, and position out of the way, any tubes or hoses attached to the air cleaner outlet tube. 2. Loosen clamps as necessary, at both ends of the air cleaner outlet tube. 3. Disconnect and remove air cleaner outlet tube. INSTALLATION Follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation Air Filter Element: Description and Operation AIR INDUCTION SYSTEM Air enters a dry-type engine air cleaner and travels through a pleated, chemically treated, water resistant paper air cleaner element to remove contaminants before entering the engine induction system. The 7.3L Direct Injection (DI) turbo diesel engine also uses a pleated-paper upright type element. Use of other than specific Ford replacement filters may result in significantly shortened filter life and consequent dirt injection. AIR CLEANER ELEMENT Dry-type engine air cleaners are standard on all light truck vehicles. The 7.3L diesel engine also uses a pleated-paper panel type air cleaner element which features an expanding foam filter media attached to the sides of the paper. Use of other than specific Ford replacement air cleaner elements may result in significantly shortened filter life and consequent engine damage. The air cleaner elements should be inspected, and/or replaced periodically according to the maintenance schedule. The air cleaner system has an Intake Air Temperature (IAT) mounted in the outlet hose to monitor engine inlet air temperature. Air Restriction Gauge On diesel engines, replace air cleaner element according to air restriction gauge. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 1209 Air Filter Element: Testing and Inspection Air Restriction Gauge Air Restriction Gauge The 7.3L diesel engine air induction system uses an air restriction indicator to indicate when to change the air cleaner element. The air cleaner element should be replaced when the yellow band in the indicator reaches the CHANGE FILTER mark. Engine performance and fuel economy are adversely affected when maximum restriction is reached. After servicing the air cleaner element, the air restriction indicator can be reset by pushing the button on the end of the indicator. The air restriction indicator is located on the clean-air side of the engine air cleaner. Air Inlet Restriction Check The best method for determining dry-type air cleaner maintenance periods on diesel equipped vehicles is by periodically checking the air restriction indicator. It is recommended that the air restriction indicator be used to determine service intervals. A visual inspection of the air cleaner element will not determine the need for service. Overservicing is not recommended. Air Cleaner Element CAUTION: If the air cleaner element, engine air cleaner or air cleaner outlet tube is removed, use a clean shop rag to prevent contaminants from entering the engine. 1. Replace the air cleaner element according to the maintenance schedule. 2. Check the old air cleaner element. It could help to detect foreign material on the sealing surface that is causing leakage. A streak of dust on the clean air side of the air cleaner element seal is the tell-tale sign. If it exists, be sure the cause is removed before installing a new air cleaner element. 3. Inspect the new air cleaner element for damage. Always look for possible shipping or handling damage. Pay particular attention to the seals. Check for cuts, etc.. Do not use a damaged air cleaner element. 4. Insert the new air cleaner element properly. Cover pressure is not necessary to compress the air cleaner element seal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 1210 Air Filter Element: Service and Repair REMOVAL CAUTION: A special filtering medium is required on Diesel engines. Use only a specific Ford replacement. Use of other Air Cleaner Elements (ACL Element) could result in serious engine damage. Do not attempt to clean ACL Element. Discard and replace. 1. Disconnect and position out of the way any tubes, hoses, or ducts that will interfere with opening the engine Air Cleaner (ACL). CAUTION: Whenever the ACL system is taken apart, use a clean shop rag to prevent contaminants from entering the air intake system. 2. Remove clamps or screws as necessary to remove ACL cover. 3. Remove the ACL cover. 4. Remove the ACL Element, being careful to not loosen any dirt or debris. INSTALLATION 1. Before installing a new ACL Element, check the following items: - Gasket surfaces should be clean and undamaged. - Inlet tube should be clean and undamaged. - ACL Element should be dry and free of holes, ruptures, dents, and damaged gaskets. - Inspect inlet snouts for possible obstructions. 2. Install new ACL Element. 3. Replace upper ACL housing. 4. Attach any tubes, hoses, or ducts as required to upper ACL housing. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information Fuel Pressure Release: Customer Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information > Page 1216 Fuel Pressure Release: Technician Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1217 Fuel Pressure Release: Service and Repair 1. Remove fuel tank filler cap to relieve any pressure in the tank. CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. 2. When servicing the fuel lines, loosen the fuel fitting to allow any residual fuel line pressure to be relieved. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order: 1-2-7-3-4-5-6-8 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression pressures are considered within specification if they are at least 350 psi and the lowest reading cylinder is within 50 psi of the highest. NOTE: Variations exceeding specifications indicate an improperly seated valve or worn/broken piston rings. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1224 Compression Check: Testing and Inspection 1. Warm engine to normal operating temperature, then turn ignition off. 2. Remove the alternator retaining bolt and electrical connectors and and position aside. 3. Remove drive belt. 4. Remove the alternator bracket retaining bolts. 5. Remove the alternator with the bracket attached. 6. Remove the dipstick assembly and bracket. 7. Remove the fuel injector wiring harness connector from the valve cover gasket. 8. Remove valve covers. 9. Unplug harness from the glow plugs and remove all glow plugs. 10. Install suitable compression gauge into cylinder No. 1 glow plug hole. 11. Crank engine at least five compression strokes with ignition switch off. Record highest reading indicated. 12. Repeat compression check on each cylinder. 13. Compression pressures are considered within specification if they are at least 350 psi and the lowest reading cylinder is within 50 psi of the highest. 14. Variations exceeding specifications indicate an improperly seated valve or worn/broken piston rings. 15. Reverse procedure to reassemble after tests. CAUTION: Do not add oil to cylinder as this may cause hydrostatic lock. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations Valve Clearance: Locations Front To Rear Left ....................................................................................................................................................... ........................................................ I-E-I-E-I-E-I-E Right .................................................................................................................................................... ......................................................... E-I-E-I-E-I-E-I Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations > Page 1228 Valve Clearance: Adjustments These engines use hydraulic lifters and there is no provision for adjustment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 03-21-14 > Oct > 03 > Drive Belts - Belt Shreds and/or Comes Off Drive Belt: All Technical Service Bulletins Drive Belts - Belt Shreds and/or Comes Off Article No. 03-21-14 10/06/03 FEAD BELT - WEARS, SHREDS, AND/OR COMES OFF - VEHICLES WITH 7.3L DIT ENGINE AND 130 AMP ALTERNATOR BUILT 8/94 THROUGH 5/96 FORD: 1995-1996 E-350, F SUPER DUTY, F-250, F-350 Article 96-17-19 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet, and to update part information and vehicle criteria. ISSUE The Front End Accessory Drive (FEAD) belt may wear, shred and/or come off during deceleration. ACTION Replace the belt tensioner and the FEAD belt. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect the belt for rear edge belt wear and move the tensioner arm to see if it can be cocked out of position. 2. Check for a sticking or binding tensioner by moving the tensioner through its full travel. 3. If any of these conditions exist, replace the belt tensioner following the procedure outlined in the appropriate model/year Service Manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-17-19 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 03-21-14 > Oct > 03 > Drive Belts - Belt Shreds and/or Comes Off Drive Belt: Customer Interest Drive Belts - Belt Shreds and/or Comes Off Article No. 03-21-14 10/06/03 FEAD BELT - WEARS, SHREDS, AND/OR COMES OFF - VEHICLES WITH 7.3L DIT ENGINE AND 130 AMP ALTERNATOR BUILT 8/94 THROUGH 5/96 FORD: 1995-1996 E-350, F SUPER DUTY, F-250, F-350 Article 96-17-19 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet, and to update part information and vehicle criteria. ISSUE The Front End Accessory Drive (FEAD) belt may wear, shred and/or come off during deceleration. ACTION Replace the belt tensioner and the FEAD belt. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect the belt for rear edge belt wear and move the tensioner arm to see if it can be cocked out of position. 2. Check for a sticking or binding tensioner by moving the tensioner through its full travel. 3. If any of these conditions exist, replace the belt tensioner following the procedure outlined in the appropriate model/year Service Manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-17-19 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1242 Drive Belt: Specifications NOTE: Tension specified is for both new belts and belts used over five minutes. Minimum Belt Tension ......................................................................................................................... ........................................................ 310 N (70 lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1243 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1244 Drive Belt: Adjustments Belt Tension, Automatically Tensioned Belts Belt Tensioner The automatic belt tensioner will maintain correct belt tension if the correct length belt is on the engine. To verify that the tensioner is working, check to see that the belt length indicator mark on the tensioner is between the maximum and minimum marks. The automatic belt tensioner has no provision for adjustment and will be damaged if forced to travel beyond its operating range. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1245 Drive Belt: Service and Repair Belt Replacement Conditions requiring belt replacement are excessive wear, severe glazing, frayed cords, etc. Replace any belt exhibiting any of these conditions. NOTE: Minor cracks in the ribbed side of the belt are considered acceptable. 1. Install a 15mm closed end wrench on the tensioner pulley bolt and rotate the tensioner arm away from the belt. 2. Remove old belt. Release tensioner slowly. Allowing the tensioner to snap back after the belt is removed may damage the tensioner. Belt Alignment CAUTION:Make sure the belt is properly seated on all pulleys. One revolution of the engine with an incorrectly seated belt may snap tensile members in the belt. 3. Install new belt over pulleys making sure that all belt ribs are correctly seated in the pulley grooves. 4. Rotate the tensioner to position it on the drive belt. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Tag, disconnect, and position out of the way, any tubes or hoses attached to the air cleaner outlet tube. 2. Loosen clamps as necessary, at both ends of the air cleaner outlet tube. 3. Disconnect and remove air cleaner outlet tube. INSTALLATION Follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation Air Filter Element: Description and Operation AIR INDUCTION SYSTEM Air enters a dry-type engine air cleaner and travels through a pleated, chemically treated, water resistant paper air cleaner element to remove contaminants before entering the engine induction system. The 7.3L Direct Injection (DI) turbo diesel engine also uses a pleated-paper upright type element. Use of other than specific Ford replacement filters may result in significantly shortened filter life and consequent dirt injection. AIR CLEANER ELEMENT Dry-type engine air cleaners are standard on all light truck vehicles. The 7.3L diesel engine also uses a pleated-paper panel type air cleaner element which features an expanding foam filter media attached to the sides of the paper. Use of other than specific Ford replacement air cleaner elements may result in significantly shortened filter life and consequent engine damage. The air cleaner elements should be inspected, and/or replaced periodically according to the maintenance schedule. The air cleaner system has an Intake Air Temperature (IAT) mounted in the outlet hose to monitor engine inlet air temperature. Air Restriction Gauge On diesel engines, replace air cleaner element according to air restriction gauge. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 1254 Air Filter Element: Testing and Inspection Air Restriction Gauge Air Restriction Gauge The 7.3L diesel engine air induction system uses an air restriction indicator to indicate when to change the air cleaner element. The air cleaner element should be replaced when the yellow band in the indicator reaches the CHANGE FILTER mark. Engine performance and fuel economy are adversely affected when maximum restriction is reached. After servicing the air cleaner element, the air restriction indicator can be reset by pushing the button on the end of the indicator. The air restriction indicator is located on the clean-air side of the engine air cleaner. Air Inlet Restriction Check The best method for determining dry-type air cleaner maintenance periods on diesel equipped vehicles is by periodically checking the air restriction indicator. It is recommended that the air restriction indicator be used to determine service intervals. A visual inspection of the air cleaner element will not determine the need for service. Overservicing is not recommended. Air Cleaner Element CAUTION: If the air cleaner element, engine air cleaner or air cleaner outlet tube is removed, use a clean shop rag to prevent contaminants from entering the engine. 1. Replace the air cleaner element according to the maintenance schedule. 2. Check the old air cleaner element. It could help to detect foreign material on the sealing surface that is causing leakage. A streak of dust on the clean air side of the air cleaner element seal is the tell-tale sign. If it exists, be sure the cause is removed before installing a new air cleaner element. 3. Inspect the new air cleaner element for damage. Always look for possible shipping or handling damage. Pay particular attention to the seals. Check for cuts, etc.. Do not use a damaged air cleaner element. 4. Insert the new air cleaner element properly. Cover pressure is not necessary to compress the air cleaner element seal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 1255 Air Filter Element: Service and Repair REMOVAL CAUTION: A special filtering medium is required on Diesel engines. Use only a specific Ford replacement. Use of other Air Cleaner Elements (ACL Element) could result in serious engine damage. Do not attempt to clean ACL Element. Discard and replace. 1. Disconnect and position out of the way any tubes, hoses, or ducts that will interfere with opening the engine Air Cleaner (ACL). CAUTION: Whenever the ACL system is taken apart, use a clean shop rag to prevent contaminants from entering the air intake system. 2. Remove clamps or screws as necessary to remove ACL cover. 3. Remove the ACL cover. 4. Remove the ACL Element, being careful to not loosen any dirt or debris. INSTALLATION 1. Before installing a new ACL Element, check the following items: - Gasket surfaces should be clean and undamaged. - Inlet tube should be clean and undamaged. - ACL Element should be dry and free of holes, ruptures, dents, and damaged gaskets. - Inspect inlet snouts for possible obstructions. 2. Install new ACL Element. 3. Replace upper ACL housing. 4. Attach any tubes, hoses, or ducts as required to upper ACL housing. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This model is not equipped with a cabin air filter Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration Fluid Filter - A/T: Customer Interest A/T - Vibration/Shudder On Light Acceleration Article No. 95-23-4 11/20/95 FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to clarify Issue, Action, Service Procedure, and Operation. ISSUE: Torque converter clutch shudder or vibration may occur under light to moderate acceleration above 56 km/h (35 mph) while in 3rd or 4th gear or during 3-4 or 4-3 shifts. This condition may be noticeable on higher mileage vehicles (24,000 km/15,000 mi or more) when the torque converter clutch engages or disengages during light to moderate acceleration. ACTION: Perform normal diagnostics (i.e., linkage adjustment fluid level and condition, On-Board diagnostic check). If self test codes are present, service as required. If no DTCs are present, perform the following Service Procedure. SERVICE PROCEDURE 1. Drain all transmission fluid. Refer to the appropriate Service Manual, Section 07-01 for details. If fluid is burnt or heavily contaminated, repair as required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 1267 2. Remove transmission and replace the torque converter assembly with the correct torque converter. Refer to Figure 1. 3. Remove the transmission pan and clean transmission pan and pan magnet. 4. Inspect transmission pan gasket and filter. Reuse both pan gasket and filter if not damaged. 5. Reinstall filter, pan magnet, and transmission pan with original gasket. 6. Completely clean and flush transmission cooler and cooler lines. 7. Reinstall the transmission assembly. 8. Refill transmission with Mercon(R) Automatic Transmission Fluid (XT-2-QDX). Use only quart containers of Mercon(R) when refilling to ensure proper fluid quality is being used. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 1268 PART NUMBER PART NAME XT-2-QDX Mercon(R) Automatic Transmission Fluid F5AZ-7902-ARM Torque Converter F5ZZ-7902-ARM Torque Converter F4LY-7902-ARM Torque Converter F4SZ-7902-BRM Torque Converter Please use the following repair description for each model described in the OPERATION/DESCRIPTION/TIME section of this TSB article: Perform electronic transmission diagnostics, replace torque converter, drain and fill transmission (including inspection of filter - replace if necessary), flush cooler and lines. Road test vehicle after repairs are complete. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-14-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952304A 1994-95 Econoline 4.6 Hrs. 952304B 1994-95 F-Series 4X2 4.4 Hrs. 952304C 1994-95 F-Series 4X4 6.0 Hrs. 952304D 1994-95 Mustang 3.8L 5.1 Hrs. 952304E 1994-95 Mustang 5.0L 5.3 Hrs. 952304F 1994-95 5.4 Hrs. Thunderbird/Cougar 4.6L 952304G 1994-95 5.3 Hrs. Thunderbird/Cougar 3.8L 952304H 1993-95 Mark VIII 5.4 Hrs. 952304I 1992-95 Crown 4.9 Hrs. Victoria/Grand Marquis/Town Car DEALER CODING CONDITION BASIC PART NO. CODE 7902 67 OASIS CODES: 501000, 502000, 504000, 510000, 597997, 703000, 703200, 703400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration Fluid Filter - A/T: All Technical Service Bulletins A/T - Vibration/Shudder On Light Acceleration Article No. 95-23-4 11/20/95 FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to clarify Issue, Action, Service Procedure, and Operation. ISSUE: Torque converter clutch shudder or vibration may occur under light to moderate acceleration above 56 km/h (35 mph) while in 3rd or 4th gear or during 3-4 or 4-3 shifts. This condition may be noticeable on higher mileage vehicles (24,000 km/15,000 mi or more) when the torque converter clutch engages or disengages during light to moderate acceleration. ACTION: Perform normal diagnostics (i.e., linkage adjustment fluid level and condition, On-Board diagnostic check). If self test codes are present, service as required. If no DTCs are present, perform the following Service Procedure. SERVICE PROCEDURE 1. Drain all transmission fluid. Refer to the appropriate Service Manual, Section 07-01 for details. If fluid is burnt or heavily contaminated, repair as required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 1274 2. Remove transmission and replace the torque converter assembly with the correct torque converter. Refer to Figure 1. 3. Remove the transmission pan and clean transmission pan and pan magnet. 4. Inspect transmission pan gasket and filter. Reuse both pan gasket and filter if not damaged. 5. Reinstall filter, pan magnet, and transmission pan with original gasket. 6. Completely clean and flush transmission cooler and cooler lines. 7. Reinstall the transmission assembly. 8. Refill transmission with Mercon(R) Automatic Transmission Fluid (XT-2-QDX). Use only quart containers of Mercon(R) when refilling to ensure proper fluid quality is being used. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 1275 PART NUMBER PART NAME XT-2-QDX Mercon(R) Automatic Transmission Fluid F5AZ-7902-ARM Torque Converter F5ZZ-7902-ARM Torque Converter F4LY-7902-ARM Torque Converter F4SZ-7902-BRM Torque Converter Please use the following repair description for each model described in the OPERATION/DESCRIPTION/TIME section of this TSB article: Perform electronic transmission diagnostics, replace torque converter, drain and fill transmission (including inspection of filter - replace if necessary), flush cooler and lines. Road test vehicle after repairs are complete. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-14-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952304A 1994-95 Econoline 4.6 Hrs. 952304B 1994-95 F-Series 4X2 4.4 Hrs. 952304C 1994-95 F-Series 4X4 6.0 Hrs. 952304D 1994-95 Mustang 3.8L 5.1 Hrs. 952304E 1994-95 Mustang 5.0L 5.3 Hrs. 952304F 1994-95 5.4 Hrs. Thunderbird/Cougar 4.6L 952304G 1994-95 5.3 Hrs. Thunderbird/Cougar 3.8L 952304H 1993-95 Mark VIII 5.4 Hrs. 952304I 1992-95 Crown 4.9 Hrs. Victoria/Grand Marquis/Town Car DEALER CODING CONDITION BASIC PART NO. CODE 7902 67 OASIS CODES: 501000, 502000, 504000, 510000, 597997, 703000, 703200, 703400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 9584 > Apr > 95 > A/T - AODE/4R70W Reusable Pan Gasket/Filter Fluid Filter - A/T: All Technical Service Bulletins A/T - AODE/4R70W Reusable Pan Gasket/Filter Article No. 95-8-4 04/24/95 ^ LEAKS - AODE/4R70W - REUSABLE PAN GASKET AND FILTER ^ TRANSMISSION - AODE/4R70W - REUSABLE PAN GASKET AND FILTER - SERVICE TIP FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to advise of updated information. ISSUE: The AODE/4R70W transmission pan gaskets and filter may be reusable. ACTION: Refer to the following to determine if the transmission pan gasket and/or filter should be reused. The AODE/4R7OW transmission pan gasket has been designed to be reusable if it is removed for a non-leak related transmission service. The gasket should be inspected for damage and cleaned, along with the mating surfaces, before reuse. If the gasket requires replacement, retain the original gasket per the parts retention and return procedures as outlined in the Warranty and Policy Manual. NOTE: THE PAN GASKET IS NOT INCLUDED IN THE GASKET AND SEAL KIT. IT CAN ONLY BE ORDERED SEPARATELY. The transmission fluid filter has also been designed to be reuseable if removed from a transmission which did not have any component failure. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-19-12 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000, 510000, 590000, 597997 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 9584 > Apr > 95 > A/T - AODE/4R70W Reusable Pan Gasket/Filter Fluid Filter - A/T: All Technical Service Bulletins A/T - AODE/4R70W Reusable Pan Gasket/Filter Article No. 95-8-4 04/24/95 ^ LEAKS - AODE/4R70W - REUSABLE PAN GASKET AND FILTER ^ TRANSMISSION - AODE/4R70W - REUSABLE PAN GASKET AND FILTER - SERVICE TIP FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to advise of updated information. ISSUE: The AODE/4R70W transmission pan gaskets and filter may be reusable. ACTION: Refer to the following to determine if the transmission pan gasket and/or filter should be reused. The AODE/4R7OW transmission pan gasket has been designed to be reusable if it is removed for a non-leak related transmission service. The gasket should be inspected for damage and cleaned, along with the mating surfaces, before reuse. If the gasket requires replacement, retain the original gasket per the parts retention and return procedures as outlined in the Warranty and Policy Manual. NOTE: THE PAN GASKET IS NOT INCLUDED IN THE GASKET AND SEAL KIT. IT CAN ONLY BE ORDERED SEPARATELY. The transmission fluid filter has also been designed to be reuseable if removed from a transmission which did not have any component failure. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-19-12 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000, 510000, 590000, 597997 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information Fuel Pressure Release: Customer Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information > Page 1290 Fuel Pressure Release: Technician Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1291 Fuel Pressure Release: Service and Repair 1. Remove fuel tank filler cap to relieve any pressure in the tank. CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. 2. When servicing the fuel lines, loosen the fuel fitting to allow any residual fuel line pressure to be relieved. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1296 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1297 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1298 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Brake Fluid Boiling Point Chart Brake Fluid: Specifications Brake Fluid Boiling Point Chart One of the key aspects of brake fluid quality is the temperature at which it boils. A comparison of the boiling points for DOT 3 (in general), Ford DOT 3 and DOT 5 brake fluids is shown. If brake fluid boils in the brake system, it forms vapor which reduces the ability of the brake system to develop hydraulic line pressure. If brake fluid boils, the system acts just like a system with air in the lines, except that it reverts to normal operation when the brakes cool and the vapor condenses. BRAKE FLUID BOILING POINTS MINIMUM FEDERAL SAFETY STANDARDS Dry Wet Dry Wet DOT 3 401° 284° 205° 140° DOT 5 500° 356° 260° 180° Ford 550° 550° 288° 288° DOT 3 Exceeds Exceeds Exceeds Exceeds Require- Require- Require- Requirements ments ments ments NOTE: A newly opened can exceeds all minimum requirements. Brake fluid absorbs moisture out of the air and must be stored in the original container with the cap securely fastened. If not, its moisture content will increase and the boiling point will drop. Moisture also will be absorbed while the fluid is in the brake system, but a properly capped and sealed brake master cylinder reservoir (2K478) will limit the rate at which this occurs. NOTE: For more brake fluid information see Fundamentals and basics. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Brake Fluid Boiling Point Chart > Page 1307 Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. Brake Fluid DOT 3 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1308 Brake Fluid: Testing and Inspection Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. The color of the brake fluid in a normal brake system in Service can vary from its original color for many reasons. Sometimes a brake master cylinder (2140) may show significantly different shades of color of brake fluid in the brake master cylinder reservoir (2K478). Some of the reasons for the apparent difference in color in a system are listed below. ^ Brake fluid discoloration can occur due to heat and/or aging. ^ Brake fluid discoloration can exist when different brands/shades of brake fluid are used in topping off during normal Service. ^ Brake fluid discoloration can occur through the dissolving of color dye used on brake master cylinder internal springs in manufacturer's assembly procedure. NOTE: Brake fluid contaminated with a hydrocarbon/mineral based fluid (power steering or transmission fluid) can be detected by an obvious swelling of the brake master cylinder filler cap gasket. If the swollen gasket condition is present, all brake system rubber parts must be replaced. All brake tubes must be thoroughly flushed with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or DOT 3 equivalent fluid meeting Ford specification ESA-M6C25-A before the vehicle goes back into Service. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1313 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1314 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1315 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1316 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 24 qts .............................................................................................................................................................. .......................................... Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1319 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration Fluid - A/T: Customer Interest A/T - Vibration/Shudder On Light Acceleration Article No. 95-23-4 11/20/95 FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to clarify Issue, Action, Service Procedure, and Operation. ISSUE: Torque converter clutch shudder or vibration may occur under light to moderate acceleration above 56 km/h (35 mph) while in 3rd or 4th gear or during 3-4 or 4-3 shifts. This condition may be noticeable on higher mileage vehicles (24,000 km/15,000 mi or more) when the torque converter clutch engages or disengages during light to moderate acceleration. ACTION: Perform normal diagnostics (i.e., linkage adjustment fluid level and condition, On-Board diagnostic check). If self test codes are present, service as required. If no DTCs are present, perform the following Service Procedure. SERVICE PROCEDURE 1. Drain all transmission fluid. Refer to the appropriate Service Manual, Section 07-01 for details. If fluid is burnt or heavily contaminated, repair as required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 1328 2. Remove transmission and replace the torque converter assembly with the correct torque converter. Refer to Figure 1. 3. Remove the transmission pan and clean transmission pan and pan magnet. 4. Inspect transmission pan gasket and filter. Reuse both pan gasket and filter if not damaged. 5. Reinstall filter, pan magnet, and transmission pan with original gasket. 6. Completely clean and flush transmission cooler and cooler lines. 7. Reinstall the transmission assembly. 8. Refill transmission with Mercon(R) Automatic Transmission Fluid (XT-2-QDX). Use only quart containers of Mercon(R) when refilling to ensure proper fluid quality is being used. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 1329 PART NUMBER PART NAME XT-2-QDX Mercon(R) Automatic Transmission Fluid F5AZ-7902-ARM Torque Converter F5ZZ-7902-ARM Torque Converter F4LY-7902-ARM Torque Converter F4SZ-7902-BRM Torque Converter Please use the following repair description for each model described in the OPERATION/DESCRIPTION/TIME section of this TSB article: Perform electronic transmission diagnostics, replace torque converter, drain and fill transmission (including inspection of filter - replace if necessary), flush cooler and lines. Road test vehicle after repairs are complete. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-14-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952304A 1994-95 Econoline 4.6 Hrs. 952304B 1994-95 F-Series 4X2 4.4 Hrs. 952304C 1994-95 F-Series 4X4 6.0 Hrs. 952304D 1994-95 Mustang 3.8L 5.1 Hrs. 952304E 1994-95 Mustang 5.0L 5.3 Hrs. 952304F 1994-95 5.4 Hrs. Thunderbird/Cougar 4.6L 952304G 1994-95 5.3 Hrs. Thunderbird/Cougar 3.8L 952304H 1993-95 Mark VIII 5.4 Hrs. 952304I 1992-95 Crown 4.9 Hrs. Victoria/Grand Marquis/Town Car DEALER CODING CONDITION BASIC PART NO. CODE 7902 67 OASIS CODES: 501000, 502000, 504000, 510000, 597997, 703000, 703200, 703400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 1335 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 1336 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration Fluid - A/T: All Technical Service Bulletins A/T - Vibration/Shudder On Light Acceleration Article No. 95-23-4 11/20/95 FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to clarify Issue, Action, Service Procedure, and Operation. ISSUE: Torque converter clutch shudder or vibration may occur under light to moderate acceleration above 56 km/h (35 mph) while in 3rd or 4th gear or during 3-4 or 4-3 shifts. This condition may be noticeable on higher mileage vehicles (24,000 km/15,000 mi or more) when the torque converter clutch engages or disengages during light to moderate acceleration. ACTION: Perform normal diagnostics (i.e., linkage adjustment fluid level and condition, On-Board diagnostic check). If self test codes are present, service as required. If no DTCs are present, perform the following Service Procedure. SERVICE PROCEDURE 1. Drain all transmission fluid. Refer to the appropriate Service Manual, Section 07-01 for details. If fluid is burnt or heavily contaminated, repair as required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 1341 2. Remove transmission and replace the torque converter assembly with the correct torque converter. Refer to Figure 1. 3. Remove the transmission pan and clean transmission pan and pan magnet. 4. Inspect transmission pan gasket and filter. Reuse both pan gasket and filter if not damaged. 5. Reinstall filter, pan magnet, and transmission pan with original gasket. 6. Completely clean and flush transmission cooler and cooler lines. 7. Reinstall the transmission assembly. 8. Refill transmission with Mercon(R) Automatic Transmission Fluid (XT-2-QDX). Use only quart containers of Mercon(R) when refilling to ensure proper fluid quality is being used. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 1342 PART NUMBER PART NAME XT-2-QDX Mercon(R) Automatic Transmission Fluid F5AZ-7902-ARM Torque Converter F5ZZ-7902-ARM Torque Converter F4LY-7902-ARM Torque Converter F4SZ-7902-BRM Torque Converter Please use the following repair description for each model described in the OPERATION/DESCRIPTION/TIME section of this TSB article: Perform electronic transmission diagnostics, replace torque converter, drain and fill transmission (including inspection of filter - replace if necessary), flush cooler and lines. Road test vehicle after repairs are complete. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-14-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952304A 1994-95 Econoline 4.6 Hrs. 952304B 1994-95 F-Series 4X2 4.4 Hrs. 952304C 1994-95 F-Series 4X4 6.0 Hrs. 952304D 1994-95 Mustang 3.8L 5.1 Hrs. 952304E 1994-95 Mustang 5.0L 5.3 Hrs. 952304F 1994-95 5.4 Hrs. Thunderbird/Cougar 4.6L 952304G 1994-95 5.3 Hrs. Thunderbird/Cougar 3.8L 952304H 1993-95 Mark VIII 5.4 Hrs. 952304I 1992-95 Crown 4.9 Hrs. Victoria/Grand Marquis/Town Car DEALER CODING CONDITION BASIC PART NO. CODE 7902 67 OASIS CODES: 501000, 502000, 504000, 510000, 597997, 703000, 703200, 703400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 1348 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 1349 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications TYPE MA CAPACITY, Initial Refill*: C-6 (deep pan) 6.0 qt (US) C-6 (shallow pan) 5.0 qt (US) E4OD: W/4x2 15.7 qt (US) W/4x4 16.2 qt (US) 4R70W: W/4x2 13.6 qt (US) W/4x4 14.6 qt (US) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1352 Fluid - A/T: Fluid Type Specifications Fluid Type ............................................................................................................................................ ............................................... MERCON(R) V ATF Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > With C6 Fluid - A/T: Testing and Inspection With C6 FLUID CHECK 1. Make sure car is on a level floor. 2. Apply parking brake firmly. 3. Run engine at normal idle speed. If transmission fluid is cold, run engine at a fast idle until fluid reaches normal operating temperature. When fluid is warm, slow engine to normal idle speed. 4. Shift selector lever through all positions, then place lever at Park. Do not shut down engine during fluid level checks. 5. Clean all dirt from dipstick cap before removing dipstick from filler tube. 6. Pull dipstick out of tube, wipe it clean, and push it all the way back in tube. 7. Pull dipstick out of tube again and check fluid level. If necessary, add specified fluid to raise the level to the Full mark on dipstick. Do not overfill. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > With C6 > Page 1355 Fluid - A/T: Testing and Inspection With E4OD FLUID CHECK NOTE: The automatic transmission is designed to operate with the fluid level between the Add and Full mark on the dipstick at an operating temperature of 150° F - 170° F. 1. With transmission in Park, engine at curb idle RPM, foot brake applied, and vehicle on level surface, move transmission selector lever through each range. 2. Allow time in each range to engage transmission, then return selector to Park. 3. Apply parking brake. NOTE: Do not turn off engine during the fluid level check. 4. Remove dipstick from filler tube, wipe clean, and push dipstick back into tube. Ensure it is fully seated. 5. Remove dipstick from filler tube and check fluid level. Fluid level should be between Add and Full mark. 6. If necessary, add enough fluid through filler tube to raise level to correct position. NOTE: Do not overfill. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > With C6 Fluid - A/T: Service and Repair With C6 FLUID CHANGE NOTE: Normal maintenance and lubrication requirements do not necessitate periodic fluid changes. If a major failure has occurred in the transmission, it will have to be removed for service. At this time the converter must be thoroughly flushed to remove any foreign matter. CAUTION: Use of a fluid other than specified could result in transmission malfunction and failure. 1. To drain the fluid, loosen pan attaching bolts and allow fluid to drain. 2. After fluid has drained to the level of the pan flange, remove pan bolts working from rear and both sides of pan to allow it to drop and drain slowly. 3. When fluid has stopped draining, remove and clean pan and screen. Discard pan gasket. 4. Using a new gasket, install pan. 5. Add recommended fluid to transmission through filler tube. 6. Run engine at idle speed for 2 minutes, and then run it at a fast idle until it reaches normal operating temperature. 7. Shift selector lever through all positions, place it at Park and check fluid level. 8. If necessary, add enough fluid to transmission to bring it to the Full mark on the dipstick. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > With C6 > Page 1358 Fluid - A/T: Service and Repair With E4OD FLUID CHANGE NOTE: No service is required on this transmission under normal use. If any of the following driving conditions exist, the transmission fluid, filter, and gasket should be changed every 21,000 miles: Sustained high speed driving at or above 90° F, towing a trailer for more than 1,000 miles, accumulating more than 5,000 miles per month or continuous running service. If service is needed proceed as follows: 1. Loosen transmission fluid pan bolts to partially drain fluid. 2. Slowly remove remaining bolts, lower pan and discard old gasket. 3. Drain torque converter by removing drain plug. 4. Reverse procedure to install, noting the following: a. Install new torque converter drain plug and torque to 18-20 ft lbs. b. Ensure the new filter and gasket application is correct. CAUTION: 4WD and 2WD are not interchangeable. Damage may result if wrong filter is installed. c. Only use MERCON transmission fluid. d. Install pan bolts and torque to 10-12 ft lbs. e. Add 6 1/2 quarts of MERCON(R) V transmission fluid. f. Check fluid and add as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Capacity M5OD (Mazda R2) 7.6 pt (US) 5-speed OD S5-42-ZF 6.8 pt (US) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1363 Fluid - M/T: Fluid Type Specifications Fluid type: Synthetic Mercon Automatic Transmission Fluid Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications TYPE: Standard 80W-90 GL-5 F150/4.10:1 axle ratio and Lightning Pickup, rear synthetic 75W-140 GL-5 Limited-Slip 80W-90 GL-5* LIMITED-SLIP OR TRACTION-LOK IDENTIFICATION: Label on door lock pillar shows letter and number CAPACITY, Refill: Rear: Ford w/8.8" ring gear 5.5 pt (US) 8.8" & 10-1/4" has removable cover. Fill 1/4" to 9/16" below fill hole w/10-1/4" ring gear 6.5 pt (US) 8.8" & 10-1/4" has removable cover Dana 60-IU 6.3 pt (US) Fill Dana axles 1/4" to 3/4" below fill hole Dana 70 except HD 6.5 pt (US) Fill Dana axles 1/4" to 3/4" below fill hole Dana 70 7.4 pt (US) Fill Dana axles 1/4" to 3/4" below fill hole Dana 80 8.3 pt (US) Fill Dana axles 1/4" to 3/4" below fill hole Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1368 Fluid - Differential: Fluid Type Specifications KEY TO LUBRICATION ABBREVIATIONS NOTE: Some manufacturer lubricant names may differ from the following list. If the manufacturer does not recommend a specific lubricant, use the following. AF Dexron(r)-III Automatic Transmission Fluid AP ATF-PLUS(r) Automatic Transmission Fluid BJ Suspension Lubricant BL Brake Lubricant CC Motor Oil, API Service CC CD Motor Oil, API Service CD CE Motor Oil, API Service CE CF-4 Motor Oil, API Service CF-4 DC Distributor Cam Lubricant EC Ethylene Glycol Coolant EP Extreme Pressure Gear Oil FA Automatic Transmission Fluid, Type F GC Wheel Bearing Grease, NLGI Classification GC GF-1 Motor Oil, API Service GF-1 (Starburst) GL-1 Gear Oil, API Service GL-1 GL-4 Gear Oil, API Service GL-4 GL-5 Gear Oil, API Service GL-5 GL-5* GL-5 Gear Oil for Limited Slip Differentials GLS Gear Lubricant, Special HB Hydraulic Brake Fluid, SAE J1703, DOT-3 or 4 HBH Hydraulic Brake Fluid, Extra Heavy Duty HG High Temperature Grease HP Hypoid Gear Oil HP* Hypoid Gear Oil for Limited Slip or Traction-Lok Differentials LB Chassis Grease, NLGI Classification LB LL Steering Linkage Lubricant LM Lithium Multipurpose Grease LS Steering Gear Lubricant MA Mercon(r) Automatic Transmission Fluid MH Manifold Heat Riser Solvent MO Motor Oil, Any API Service Classification PC Carburetor Cleaner PS Power Steering Fluid SF Motor Oil, API service SF SG Motor Oil, API service SG SH Motor Oil, API service SH SLF Special Lubricant - Fluid SLS Special Lubricant - Spray WB Wheel Bearing Grease Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Motor Oil - Viscosity Grade Recommendation Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Refill (all models) ................................................................................................................................. .......................................................... 12 Qts.(11.4L) Note: Add 2 Qts.(1.9L) when replacing oil filter. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1375 Engine Oil: Fluid Type Specifications Ford Part Name - Motorcraft Motor Oil 15W40 Super Duty SAE-30 Super Duty Ford Part Number - XO-15W40-QSD - XO-30-QSD Ford Supplication - API SG/CE or SG/CD and ESE-M2C153-E Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1380 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1381 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1382 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1383 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1384 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1385 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1386 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1387 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1388 Refrigerant: Technical Service Bulletins A/C - Release of R134a Fluorescent Dye Article No. 94-26-6 12/26/94 AIR CONDITIONING - RELEASE OF R-134A FLUORESCENT TRACER DYE - FOR 1992 TAURUS, R-134A VEHICLES ONLY - SERVICE TIP FORD: 1992-95 TAURUS 1994-95 ASPIRE, CROWN VICTORIA, ESCORT, MUSTANG, PROBE, THUNDERBIRD 1994 TEMPO 1995 CONTOUR LINCOLN-MERCURY: 1993-95 MARK VIII 1994-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1994 CAPRI, TOPAZ 1995 MYSTIQUE LIGHT TRUCK: 1994-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995 WINDSTAR ISSUE: Ford Motor Company has approved an R-134a Fluorescent Tracer Dye (Rotunda Part, 112-ROO40) for use in checking R-134a A/C systems for refrigerant leaks. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1389 ACTION: When leak checking an R-134a system, install the 112-R0040 dye using a Rotunda Dye lnjector (164-R2610). Use the procedures in Figure 1 when leak checking. This method of leak detection is an approved alternate to electronic leak detection and vacuum decay leak detection. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications With Front A/C A/C Refrigerant Capacity (Front Only) ................................................................................................. ...................................................................... 52 oz With Front and Rear A/C A/C Refrigerant Capacity (Front and Rear Only) ........................................................................................................................................................ 64 oz Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1392 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ....................................................................... R-134a Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > Customer Interest: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure Refrigerant Oil: Customer Interest A/C - Insufficient Cooling/ Compressor Failure Article No. 97-10-5 05/12/97 ^ AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL ^ AIR CONDITIONING - LACK OF COOLING - INSUFFICIENT AMOUNT OF REFRIGERANT OIL MAY CAUSE COMPRESSOR FAILURE FORD: 1994-97 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1994-97 COUGAR LIGHT TRUCK: 1993-96 BRONCO 1993-97 F-150-350 SERIES, F-47 1994-95 ECONOLINE 1994-96 VILLAGER 1994-97 AEROSTAR, EXPLORER, RANGER 1995-96 WINDSTAR 1997 MOUNTAINEER This TSB article is being republished in its entirety to include 1997 F-Series. ISSUE: Some vehicles may exhibit air conditioner compressor failure due to an insufficient amount of refrigerant oil in the system. ACTION: Whenever service is required on the A/C system, add the appropriate refrigerant oil to the system. Refer to the following Service Procedure for details. NOTE: USE MOTORCRAFT YN-9 REFRIGERANT COMPRESSOR OIL FOR 1993 MODELS EQUIPPED WITH AN R-12 SYSTEM. FOR 1994 AND LATER MODELS USING AN R-134a SYSTEM, USE MOTORCRAFT YN-12-B POLYALKYLENE GLYCOL (PAG) REFRIGERANT COMPRESSOR OIL. SERVICE PROCEDURE 1. Remove all refrigerant from the A/C system using the appropriate R-12 or R-134a refrigerant recovery equipment following the manufacturer's operating instructions. 2. Service the A/C system as required. 3. Check for Modification Label indicating additional refrigerant oil is already in place. 4. If no label was found, add additional clean refrigerant oil (over and above the amount of oil required for the system being serviced). The oil may be poured directly into the accumulator assembly or it may be injected by the refrigerant charging station, if so equipped. 5. Recharge the A/C system using the appropriate refrigerant. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > Customer Interest: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure > Page 1401 Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) 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. PART NUMBER PART NAME YN-9 Refrigerant Oil (R-12 Systems) YN-12-B Refrigerant Oil (R-134a Systems) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity Refrigerant Oil: All Technical Service Bulletins A/C - Refrigerant Oil Refill Capacity Article No. 97-15-5 07/21/97 AIR CONDITIONING - OIL REFILL CAPACITY CHART - SERVICE TIP FORD: 1994 TEMPO 1994-97 ASPIRE, PROBE, THUNDERBIRD 1994-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1994 CAPRI, TOPAZ 1994-97 COUGAR 1994-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1994-96 BRONCO 1994-97 AEROSTAR 1994-98 ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: This TSB article will provide an easy and quick reference chart for determining the correct amount of refrigerant oil to use when servicing an A/C system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity > Page 1407 ACTION: Refer to Figure 1 to determine how much refrigerant oil is needed to service an A/C system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure Refrigerant Oil: All Technical Service Bulletins A/C - Insufficient Cooling/ Compressor Failure Article No. 97-10-5 05/12/97 ^ AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL ^ AIR CONDITIONING - LACK OF COOLING - INSUFFICIENT AMOUNT OF REFRIGERANT OIL MAY CAUSE COMPRESSOR FAILURE FORD: 1994-97 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1994-97 COUGAR LIGHT TRUCK: 1993-96 BRONCO 1993-97 F-150-350 SERIES, F-47 1994-95 ECONOLINE 1994-96 VILLAGER 1994-97 AEROSTAR, EXPLORER, RANGER 1995-96 WINDSTAR 1997 MOUNTAINEER This TSB article is being republished in its entirety to include 1997 F-Series. ISSUE: Some vehicles may exhibit air conditioner compressor failure due to an insufficient amount of refrigerant oil in the system. ACTION: Whenever service is required on the A/C system, add the appropriate refrigerant oil to the system. Refer to the following Service Procedure for details. NOTE: USE MOTORCRAFT YN-9 REFRIGERANT COMPRESSOR OIL FOR 1993 MODELS EQUIPPED WITH AN R-12 SYSTEM. FOR 1994 AND LATER MODELS USING AN R-134a SYSTEM, USE MOTORCRAFT YN-12-B POLYALKYLENE GLYCOL (PAG) REFRIGERANT COMPRESSOR OIL. SERVICE PROCEDURE 1. Remove all refrigerant from the A/C system using the appropriate R-12 or R-134a refrigerant recovery equipment following the manufacturer's operating instructions. 2. Service the A/C system as required. 3. Check for Modification Label indicating additional refrigerant oil is already in place. 4. If no label was found, add additional clean refrigerant oil (over and above the amount of oil required for the system being serviced). The oil may be poured directly into the accumulator assembly or it may be injected by the refrigerant charging station, if so equipped. 5. Recharge the A/C system using the appropriate refrigerant. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure > Page 1412 Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) 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. PART NUMBER PART NAME YN-9 Refrigerant Oil (R-12 Systems) YN-12-B Refrigerant Oil (R-134a Systems) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 961015 > May > 96 > Air Conditioning - Oil Refill And Charge Service Tip Refrigerant Oil: All Technical Service Bulletins Air Conditioning - Oil Refill And Charge Service Tip Article No. 96-10-15 05/06/96 AIR CONDITIONING - REFRIGERANT OIL REFILL AND CHARGE SERVICE TIP LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The refrigerant oil and charge levels for 1995-96 Econolines have changed. ACTION: When servicing or installing Add-On or Aftermarket A/C systems on these vehicles, it is important to note the proper refrigerant and oil levels to prevent A/C system failure. Refer to the Capacity Chart for correct refill levels. PART NUMBER PART NAME YN-16 R-134a Refrigerant F2AZ-19577-AC Refrigerant Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 95512 > Mar > 95 > A/C - Adding Refrigerant Oil Service Tip Refrigerant Oil: All Technical Service Bulletins A/C - Adding Refrigerant Oil Service Tip Article No. 95-5-12 03/13/95 AIR CONDITIONING - ADDING REFRIGERANT OIL - SERVICE TIP FORD: 1990-93 FESTIVA 1990-94 TEMPO 1990-95 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-95 ASPIRE LINCOLN-MERCURY: 1990-92 MARK VII 1990-94 TOPAZ 1990-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-94 CAPRI 1993-95 MARK VIII MERKUR: 1990 SCORPIO LIGHT TRUCK: 1990 BRONCO II 1990-95 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-95 EXPLORER 1993-95 VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-91 C SERIES, CL-CLT-9000 SERIES 1990-95 CARGO SERIES, F & B SERIES, L SERIES ISSUE: Current repair procedures do not advise on the addition of refrigerant oil to the A/C system when a minor repair is made. ACTION: Add 0.06 L (2 oz) of the proper type new refrigerant oil to the system,. before recharging, when servicing concerns that do not require major component replacement. Repairs considered minor are: O-ring leaks, charge port leaks, Pressure Relief Valve (PRV) leaks, compressor shaft seal leaks, hose leaks, etc. Remember to use polyalkylene glycol (PAG) oil with R-134a systems and mineral oil with R-12 systems. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity Refrigerant Oil: All Technical Service Bulletins A/C - Refrigerant Oil Refill Capacity Article No. 97-15-5 07/21/97 AIR CONDITIONING - OIL REFILL CAPACITY CHART - SERVICE TIP FORD: 1994 TEMPO 1994-97 ASPIRE, PROBE, THUNDERBIRD 1994-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1994 CAPRI, TOPAZ 1994-97 COUGAR 1994-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1994-96 BRONCO 1994-97 AEROSTAR 1994-98 ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: This TSB article will provide an easy and quick reference chart for determining the correct amount of refrigerant oil to use when servicing an A/C system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity > Page 1426 ACTION: Refer to Figure 1 to determine how much refrigerant oil is needed to service an A/C system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 961015 > May > 96 > Air Conditioning - Oil Refill And Charge Service Tip Refrigerant Oil: All Technical Service Bulletins Air Conditioning - Oil Refill And Charge Service Tip Article No. 96-10-15 05/06/96 AIR CONDITIONING - REFRIGERANT OIL REFILL AND CHARGE SERVICE TIP LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The refrigerant oil and charge levels for 1995-96 Econolines have changed. ACTION: When servicing or installing Add-On or Aftermarket A/C systems on these vehicles, it is important to note the proper refrigerant and oil levels to prevent A/C system failure. Refer to the Capacity Chart for correct refill levels. PART NUMBER PART NAME YN-16 R-134a Refrigerant F2AZ-19577-AC Refrigerant Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 95512 > Mar > 95 > A/C - Adding Refrigerant Oil Service Tip Refrigerant Oil: All Technical Service Bulletins A/C - Adding Refrigerant Oil Service Tip Article No. 95-5-12 03/13/95 AIR CONDITIONING - ADDING REFRIGERANT OIL - SERVICE TIP FORD: 1990-93 FESTIVA 1990-94 TEMPO 1990-95 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-95 ASPIRE LINCOLN-MERCURY: 1990-92 MARK VII 1990-94 TOPAZ 1990-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-94 CAPRI 1993-95 MARK VIII MERKUR: 1990 SCORPIO LIGHT TRUCK: 1990 BRONCO II 1990-95 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-95 EXPLORER 1993-95 VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-91 C SERIES, CL-CLT-9000 SERIES 1990-95 CARGO SERIES, F & B SERIES, L SERIES ISSUE: Current repair procedures do not advise on the addition of refrigerant oil to the A/C system when a minor repair is made. ACTION: Add 0.06 L (2 oz) of the proper type new refrigerant oil to the system,. before recharging, when servicing concerns that do not require major component replacement. Repairs considered minor are: O-ring leaks, charge port leaks, Pressure Relief Valve (PRV) leaks, compressor shaft seal leaks, hose leaks, etc. Remember to use polyalkylene glycol (PAG) oil with R-134a systems and mineral oil with R-12 systems. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications With Front A/C Refrigerant Oil System Capacity ......................................................................................................... ......................................................................... 7.0 oz With Front and Rear A/C Refrigerant Oil System Capacity ......................................................................................................... ....................................................................... 10.0 oz Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1437 Refrigerant Oil: Fluid Type Specifications Polyalkylene Glycol (PAG) ........................................................................................................................................ WSH-M1C231-B Motorcraft YN-12c Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding NOTE: Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from hydraulic system. 1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to absorb escaping brake fluid. 2. Depress brake pedal slowly forcing air trapped in master cylinder out at fitting. 3. Hold pedal down and tighten fittings, then release brake pedal. NOTE: Releasing brake pedal before fittings are tightened will allow air to enter the master cylinder. 4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm. 5. Bleed brakes as follows: RR, LR, ABS valve, RF, LF 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, 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 the Rear Antilock Brake System (RABS) valve. 7. Bleed the front brakes using same procedure as for rear brakes. 8. Fill master cylinder to 1/4 inch from top of reservoir or to the proper fill line indicated on the fluid reservoir. 9. Centralize pressure differential control valve, if applicable, as follows: a. Turn ignition switch to ACC or ON position. b. Push brake pedal down, allow piston to center itself, turning off warning light. c. Turn ignition switch to the OFF position. 10. Check brake operation and ensure pedal is firm, road test vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 1442 Brake Bleeding: Service and Repair Master Cylinder Bleeding 1. Support the master cylinder body in a vise, and fill both fluid reservoirs with heavy duty DOT 3 brake fluid. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake outlet system first. 3. Loosen the plug in the front brake outlet port. Depress the secondary piston slowly to force the air out of the master cylinder. Tighten plug while piston is depressed or air will enter the master cylinder. 4. Repeat this procedure until air ceases to exit at the outlet port. 5. Repeat steps 3 and 4 for the rear brake outlet port with the front brake outlet plugged. 6. Tighten the plugs and try to depress the piston. Depressing the piston should be harder after all air is expelled. 7. Install the plastic cap. 8. Install the master cylinder in the vehicle and bleed the hydraulic system. NOTE: For additional information see Notes, Warnings, and Hints. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 1443 Brake Bleeding: Service and Repair Pressure Bleeding Be sure the bleeder tank contains enough of the specified brake fluid to complete the bleeding operation. Charge the tank with approximately 69-206 kPa (10-30 psi). Never exceed 345 kPa (50 psi). Never use brake fluid that has been drained from the hydraulic system. Bleed the longest lines first 1. Clean all dirt from the master cylinder reservoir cap. 2. Remove the master cylinder reservoir cap and fill the master cylinder reservoir with the specified brake fluid. Install the pressure bleeder adapter tool on the master cylinder, and attach the bleeder tank hose to the fitting on the adapter. NOTE: Master cylinder pressure bleeder adapter tools are available from the manufacturers of pressure bleeding equipment. Follow the manufacturer's instructions when installing the adapter. 3. Place a 3/8 inch box wrench on the bleeder fitting on the right rear brake wheel cylinder. Attach a bleeder tube snugly to the bleeder fitting. 4. Open the valve on the bleeder tank and admit pressurized brake fluid to the master cylinder reservoir. 5. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen the bleeder fitting. 6. When air bubbles no longer appear in the fluid at the submerged end of the bleeder tube, close the bleeder fitting and remove the tube. 7. Repeat Steps 3 through 6 at the opposite wheel cylinder. On front brakes, bleed the right front caliper first. 8. When the bleeding operation is completed, close the bleeder tank valve and remove the tank hose from the adapter fitting. 9. Remove the pressure bleeder adapter tool. Fill the master cylinder reservoirs with the specified brake fluid to within 3 mm (1/8 in) from the top of the filler neck. Install the master cylinder cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 1444 Brake Bleeding: Service and Repair Priming Brake System When a brake master cylinder (2140) has been installed, or the brake system emptied or partially emptied, fluid may not flow from the wheel cylinder bleeder screws during normal bleeding. It may be necessary to prime the brake master cylinder using the following procedure: 1. Use a tubing wrench to remove the front brake tube (2264) and the brake master cylinder outlet rear tube from the brake master cylinder. 2. Install short brake tubes in the brake master cylinder and position them so that they curve into the brake master cylinder reservoir, and the ends of the tubes are submerged in brake fluid. 3. Fill the brake master cylinder reservoir (2K478) with new Ford High-Performance DOT 3 Brake Fluid C6AZ-19542-AA or -BA or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 4. Have an assistant pump the brakes until clear, bubble-free fluid flows from both brake tubes. 5. Remove the short brake tubes and reinstall the front brake tube and brake master cylinder outlet rear tube (2B253) on the brake master cylinder. 6. Bleed each brake tube at the brake master cylinder using the following procedure: a. Have an assistant pump the brake pedal (2455) 10 times and then hold firm pressure on the brake pedal. b.Loosen the rearmost brake tube fittings with a tubing wrench until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal until the brake tube fitting is tightened again. c. Repeat this operation until clear, bubble-free fluid comes out from around the tube fitting. Refill the brake master cylinder reservoir as necessary. d. Repeat this bleeding operation at the front brake tube fittings. 7. If any of the brake tubes, disc brake calipers (2B120), or rear wheel cylinders have been removed, it may be helpful to prime the system by gravity bleeding. This should be done after the brake master cylinder is primed and bled. To gravity bleed the brake system: a. Fill the brake master cylinder with new Heavy-Duty Brake Fluid C6AZ-19542-AA or -BA or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. b. Loosen both of the wheel cylinder bleeder screws and leave them open until clear brake fluid flows. Be sure to check the brake master cylinder reservoir fluid level often and do not let it run dry. c. Tighten the wheel cylinder bleeder screws (2208) to 7-9 Nm (61-87 in lb). d. One at a time, loosen the caliper bleeder screws. Leave the bleeder screws open until clear fluid flows. Check the fluid level often in the brake master cylinder reservoir and do not let it run dry. e. Tighten the caliper bleeder screws to 17-24 Nm (12-17 ft lb). 8. After the brake system has been primed, bleed the brake system at each wheel (1007). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 1445 Brake Bleeding: Service and Repair With ABS SPECIAL TOOLS NEEDED Description Tool Number Antilock Brake Adapter (Bleeder Box) T90P-50-ALA Antilock Brake Adapter T93T-50-ALA (Jumper Cable) EEC-IV Breakout Box T83L-50-EEC-IV CAUTION: Perform this procedure only if the Hydraulic Control Unit (HCU) has been replaced. Follow conventional bleed procedures if the HCU is not being replaced. 1. Perform conventional brake system bleed. 2. Connect Antilock Brake Adapter T90P-50-ALA (bleeder box) and Antilock Brake Adapter T93T-50-ALA (jumper cable). 3. Press down on the brake pedal (2455) and depress the VALVES button on the bleeder box ( brake pedal will fall). 4. Release the VALVES button and release the brake pedal. 5. Repeat above two steps once more. 6. Depress the MOTOR START button and let the pump motor run for one minute. 7. Perform conventional brake system bleed. ANTILOCK BRAKE ADAPTER CONTROLS Item Part Number Description 1 T90P-50-ALA Anti-Lock Brake Adapter (Part of T90P-50-ALA) 2 -- Bleed/Harness Selector (Part of T90P -50-ALA) 3 -- Green "Motor On" Lamp (Part of T90P -50-ALA) 4 -- Red "Motor Off" Lamp (Part of T90P-50-ALA) 5 -- Valve Button (Part of T90P-50-ALA) 6 -- Abort Button (Part of T90P-50-ALA) 7 -- Motor Start Button (Part of T90P-50-ALA) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver side air bag module connector. 5. Connect Rotunda Air Bag Simulator 105-00010 or equivalent to vehicle harness at top of steering wheel. 6. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. REACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute for backup power supply to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. Reconnect driver air bag module connector. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten nut and washer assemblies 4-6 Nm (36-53 lb-in). 4. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 5. Prove out system. Refer to System Prove Out Procedure under Testing and Inspection / Procedures / Diagnostic Strategies. WARNING: THE AIR BAG SIMULATOR(S) MUST BE REMOVED AND THE DRIVER SIDE AIR BAG MODULE RECONNECTED FOR THE SYSTEM TO BE REACTIVATED. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 1450 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Are center sensor and frame rail sensor connected and mounted to vehicle? ........................................................................................................... [ ] 2. Is right cowl side sensor connected and mounted to vehicle? ................................................................................................................................... [ ] 3. Is gray three-way connector at base of steering column connected? ........................................................................................................................ [ ] 4. Is air bag or air bag simulator connected? ...................................................................................... .......................................................................... [ ] 5. Is air bag diagnostic monitor connected? ........................................................................................ ......................................................................... [ ] 6. Is vehicle battery connected? .......................................................................................................... .......................................................................... [ ] Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1456 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1457 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1458 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1459 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1460 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1461 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1462 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1463 Circuit Breaker: Electrical Diagrams Circuit Breaker 12 For wiring diagrams, please refer to Starting and Charging/Power and Ground Distribution/Diagrams/Electrical/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit Breaker 12. See: Diagrams/Electrical Diagrams/Power and Ground Distribution/System Diagram/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit Breaker 12 Circuit Breaker 14 For wiring diagrams, please refer to Starting and Charging/Power and Ground Distribution/Diagrams/Electrical/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit Breaker 14. See: Diagrams/Electrical Diagrams/Power and Ground Distribution/System Diagram/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit Breaker 14 Circuit-To-Circuit Breaker Cross Reference For wiring diagrams, please refer to Starting and Charging/Power and Ground Distribution/Diagrams/Electrical/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit-to-Circuit Breaker Cross Reference. See: Diagrams/Electrical Diagrams/Power and Ground Distribution/System Diagram/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit-to-Circuit Breaker Cross Reference Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 961418 > Jul > 96 > Mega Fuse - Vibration Breakage Fuse: Customer Interest Mega Fuse - Vibration Breakage Article No. 96-14-18 07/01/96 MEGA FUSE - VIBRATION CAUSES MEGA FUSE TO OPEN - AMBULANCE CONVERSIONS WITH 7.3L DIT ONLY LIGHT TRUCK: 1995-96 E-350 ISSUE: Ambulance conversion companies modify the electrical distribution system in E-350 vehicles with 7.3L DIT engines. These modifications to the original equipment wiring in the area of the Mega Fuse may decrease the strain relief which results in vibration of the Mega Fuse. This vibration may lead to breakage of the fuse at the point of highest stress. ACTION: Replace the Mega Fuse (Figure 1) with a shunt. The shunt should reduce the possibility of fuse breakage caused by vibration. Refer to the following text for details. Contact the original conversion company to discuss the replacement of the Mega Fuse. If the original conversion company approves of the replacement, remove the Mega Fuse and replace it with a shunt. Torque the Mega Fuse holder to 12-18 N-m (9-13 lb-ft). PART NUMBER PART NAME F6UZ-11A086-AA Shunt OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961418A Install Shunt 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 11A086 X6 OASIS CODES: 203000, 203200, 603300, 607000, 614000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 961418 > Jul > 96 > Mega Fuse - Vibration Breakage Fuse: All Technical Service Bulletins Mega Fuse - Vibration Breakage Article No. 96-14-18 07/01/96 MEGA FUSE - VIBRATION CAUSES MEGA FUSE TO OPEN - AMBULANCE CONVERSIONS WITH 7.3L DIT ONLY LIGHT TRUCK: 1995-96 E-350 ISSUE: Ambulance conversion companies modify the electrical distribution system in E-350 vehicles with 7.3L DIT engines. These modifications to the original equipment wiring in the area of the Mega Fuse may decrease the strain relief which results in vibration of the Mega Fuse. This vibration may lead to breakage of the fuse at the point of highest stress. ACTION: Replace the Mega Fuse (Figure 1) with a shunt. The shunt should reduce the possibility of fuse breakage caused by vibration. Refer to the following text for details. Contact the original conversion company to discuss the replacement of the Mega Fuse. If the original conversion company approves of the replacement, remove the Mega Fuse and replace it with a shunt. Torque the Mega Fuse holder to 12-18 N-m (9-13 lb-ft). PART NUMBER PART NAME F6UZ-11A086-AA Shunt OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961418A Install Shunt 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 11A086 X6 OASIS CODES: 203000, 203200, 603300, 607000, 614000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1479 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1480 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1481 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1482 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1483 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1484 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1485 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1486 Fuse: Electrical Diagrams Circuit-to-Fuse Cross Reference 4 Wheel Anti-Lock Brakes System Relay ........................................................................................................................................................... Fuse U & V Auxiliary A/C-Heater ......................................................................................................... ......................................................................................... Fuse A Blower Motor Relay ....................... .............................................................................................................................................................. ............... Fuse F Class I Trailer Running Lamps ................................................................................ .................................................................................................... Fuse P Class II Trailer Running Lamps Relay ........................................................................................................................................ ................................ Fuse P Daytime Running Lamps Module ........................................................... .................................................................................................................... Fuse R Electronic Brake . .............................................................................................................................................................. .......................................... Fuse D Fuse 1 .......................................................................................... ................................................................................................................................ Fuse S Fuse 10 .. .............................................................................................................................................................. ........................................................ Fuse F Fuse 12 .......................................................................... .............................................................................................................................................. Fuse S Fuse 15 ................................................................................................................................................ ........................................................................ Fuse G Fuse 16 .......................................................... .............................................................................................................................................................. Fuse S Fuse 4 ..................................................................................................................................... ..................................................................................... Fuse S Fuse 8 ............................................... .............................................................................................................................................................. ............. Fuse S Fuse R ....................................................................................................................... ................................................................................................... Fuse S Heated Oxygen Sensor ....... .............................................................................................................................................................. ........................... Fuse G Hood Lamp ................................................................................................. ................................................................................................................ Fuse R Horn Relay ............. .............................................................................................................................................................. ....................................... Fuse R Ignition Switch ................................................................................. ........................................................................................................................... Fuse G Ignition System ................................................................................................................................................. .......................................................... Fuse U Instrument Cluster ........................................................ ............................................................................................................................................... Fuse U Main Light Switch ................................................................................................................................ ....................................................................... Fuse S Modified Vehicle Power ................................... .................................................................................................................................................... Fuse B & J PCM Power Relay ...................................................................................................................... ................................................................................ Fuse U Plug-in Diode ......................................... .............................................................................................................................................................. ....... Fuse L Power Lumbar Seats ....................................................................................................... ............................................................................................. Fuse E Power Seats .............................. .............................................................................................................................................................. ..................... Fuse E Remote Keyless Entry Module .......................................................................... ......................................................................................................... Fuse A Trailer Adapter Battery Feed .................................................................................................................................................... ................................... Fuse J Trailer Backup Lamp Relay ................................................................. ....................................................................................................................... Fuse K Trailer Battery Charge Relay ....................................................................................................................................... ................................................ Fuse J Trailer LH Turn/Stop Lamp ..................................................... ................................................................................................................................... Fuse N Trailer RH Turn/Stop Lamp ............................................................................................................................. .......................................................... Fuse M Trailer Running Lamp Relay ........................................ .............................................................................................................................................. Fuse K Fuse A Fuse A - protects the following circuits: ^ Auxiliary A/C-Heater ^ Remote Keyless Entry Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1487 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1488 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1489 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1490 Power Distribution Fuse B Fuse B - protects the following circuits: ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1491 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1492 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1493 Power Distribution Fuse D Fuse D - protects the following circuits: ^ Electronic Brake Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1494 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1495 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1496 Power Distribution Fuse E Fuse E - protects the following circuits: ^ Power Seats ^ Power Lumbar Seats Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1497 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1498 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1499 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1500 Power Distribution Fuse F Fuse F - protects the following circuits: ^ Blower Motor Relay ^ Fuse 10 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1501 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1502 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1503 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1504 Power Distribution Fuse G Fuse G - protects the following circuits: ^ Ignition Switch ^ Fuse 15 ^ Heated Oxygen Sensor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1505 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1506 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1507 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1508 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1509 Power Distribution Fuse J Fuse J - protects the following circuits: ^ Trailer Battery Charge Relay ^ Trailer Adapter Battery Feed ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1510 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1511 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1512 Power Distribution Fuse K Fuse K - protects the following circuits: ^ Trailer Backup Lamp Relay ^ Trailer Running Lamp Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1513 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1514 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1515 Power Distribution Fuse M Fuse M - protects the following circuits: ^ Trailer RH Turn/Stop Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1516 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1517 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1518 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1519 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1520 Power Distribution Fuse N Fuse N - protects the following circuits: ^ Trailer LH Turn/Stop Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1521 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1522 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1523 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1524 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1525 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1526 Power Distribution Fuse P Fuse P - protects the following circuits: ^ Class I Trailer Running Lamps ^ Class II Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1527 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1528 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1529 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1530 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1531 Power Distribution Fuse S Fuse S - protects the following circuits: ^ Fuse 1 ^ Fuse 4 ^ Fuse 8 ^ Fuse 12 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1532 ^ Fuse 16 ^ Fuse R ^ Main Light Switch Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1533 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1534 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1535 Power Distribution Fuse U Fuse U - protects the following circuits: ^ Ignition System ^ Instrument Cluster ^ Part In Assembly Engine ^ PCM Power Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1536 ^ 4 Wheel Anti-Lock Brakes System Relay Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1537 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1538 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1539 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1540 Power Distribution Fuse V Fuse V - protects the following circuits: ^ 4 Wheel Anti-Lock Brakes System Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1541 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1542 Power Distribution Circuit-to-Fuse Cross Reference Accessory Tap ..................................................................................................................................... ........................................................................ Fuse 6 Air Bag Module ............................................... ................................................................................................................................................... Fuse 5 & 15 Anti-Theft Indicator ................................................................................................................... .................................................................................. Fuse 8 Anti-Theft Module ................................. .............................................................................................................................................................. . Fuse 6 & 7 Auxiliary Battery Relay .................................................................................................... ........................................................................................... Fuse 5 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1543 Backup Lamps ..................................................................................................................................... ........................................................................ Fuse 5 Blend Door Actuator ....................................... ............................................................................................................................................................ Fuse 9 Brake Pressure Switch ............................................................................................................ ..................................................................................... Fuse 1 Cigar Lighter ...................................... .............................................................................................................................................................. .......... Fuse 10 Courtesy Lamp Switch ................................................................................................ ................................................................................................. Fuse 8 Data Link Connector .............. .............................................................................................................................................................. ........................ Fuse 1 Daytime Running Lamps Module ................................................................... ............................................................................................................. Fuse 5 Dome/Map Lamp ....... .............................................................................................................................................................. .................................... Fuse 8 Flash to Pass ...................................................................................... .......................................................................................................................... Fuse 4 Function Selector Switch .................................................................................................................................... ......................................................... Fuse 9 Hazard Lamps ............................................................... ............................................................................................................................................... Fuse 5 Head and Park Lamp ........................................................................................................................... ........................................................................ Fuse 4 Illuminated Entry ............................................. ..................................................................................................................................................... Fuse 6 & 8 Instrument Illumination ............................................................................................................... ................................................................................. Fuse 4 Instrument Panel Illumination Lamps .... .............................................................................................................................................................. ...... Fuse 13 License Lamps ............................................................................................................... .............................................................................................. Fuse 4 Main Light Switch ..................... .............................................................................................................................................................. .................. Fuse 11 Modified Vehicle Power ...................................................................................... ...................................................................................................... Fuse 16 Park/Neutral Position Switch .................................................................................................................................................. ..................................... Fuse 7 Power Amplifier ................................................................................. ....................................................................................................................... Fuse 10 Power Lumbar Seats ................................................................................................................................................... ............................................... Fuse 16 Power Mirrors ........................................................................ ...................................................................................................................................... Fuse 8 Powertrain Control Module .................................................................................................................. ....................................................................... Fuse 7 Programmable Speedometer/Odometer Module ................................................................................................................................................. Fuse 1 & 17 Radio ............................................................................................................................... .......................................................................................... Fuse 11 Radio Memory ............................ .............................................................................................................................................................. ................... Fuse 8 Rear Anti-Lock Brakes System ............................................................................ ...................................................................................................... Fuse 17 Rear Power Outlet .......... .............................................................................................................................................................. .............................. Fuse 10 Remote Keyless Entry Module ............................................................... .............................................................................................................. Fuse 6 & 8 Shift Lock Actuator ............................................................................................................................................... ...................................................... Fuse 5 Speed Control ................................................................... .................................................................................................................................... Fuse 1 & 6 Trailer Battery Charge Relay ............................................................................................................... ........................................................................ Fuse 6 Transmission Control Switch .......................... ............................................................................................................................................................. Fuse 5 Transmission Range Sensor ................................................................................................... ...................................................................................... Fuse 7 Turn Lamps ...................................... .............................................................................................................................................................. .............. Fuse 5 Turn/Stop/Hazard Lamp ........................................................................................... ................................................................................................... Fuse 1 Visor Lamps ......................... .............................................................................................................................................................. ......................... Fuse 8 Warning Chime .............................................................................................. ............................................................................................................ Fuse 18 Warning Indicators .... .............................................................................................................................................................. .................................. Fuse 18 Windshield Wiper Motor ..................................................................... ........................................................................................................................ Fuse 2 Wiper Control Module ................................................................................................................................................. ................................................ Fuse 2 Fuse 1 Fuse 1 - protects the following circuits: ^ Turn/Stop/Hazard Lamp ^ Speed Control ^ Data Link Connector ^ Brake Pressure Switch ^ Programmable Speedometer/Odometer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1544 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1545 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1546 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1547 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1548 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Windshield Wiper Motor ^ Wiper Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1549 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1550 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1551 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1552 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ License Lamps ^ Flash to Pass ^ Instrument Illumination ^ Head and Park Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1553 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1554 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1555 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1556 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1557 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Air Bag Module ^ Daytime Running Lamps Module ^ Auxiliary Battery Relay ^ Shift Lock Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1558 ^ Transmission Control Switch ^ Backup Lamps ^ Turn Lamps ^ Hazard Lamps Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1559 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1560 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1561 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1562 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1563 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1564 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Speed Control ^ Remote Keyless Entry Module ^ Illuminated Entry ^ Accessory Tap Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1565 ^ Anti-Theft Module ^ Trailer Battery Charge Relay Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1566 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1567 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1568 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1569 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: ^ Anti-Theft Module ^ Transmission Range Sensor ^ Park/Neutral Position Switch ^ Powertrain Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1570 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1571 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1572 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1573 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1574 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Courtesy Lamp Switch ^ Illuminated Entry ^ Power Mirrors ^ Visor Lamps Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1575 ^ Anti-Theft Indicator ^ Radio Memory ^ Dome/Map Lamp ^ Remote Keyless Entry Module Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1576 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1577 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1578 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1579 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1580 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1581 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: ^ Function Selector Switch ^ Blend Door Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1582 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1583 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1584 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1585 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: ^ Cigar Lighter ^ Rear Power Outlet ^ Power Amplifier Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1586 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1587 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1588 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1589 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Radio ^ Main Light Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1590 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1591 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1592 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1593 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1594 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Instrument Panel Illumination Lamps Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1595 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1596 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1597 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1598 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1599 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Air Bag Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1600 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1601 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1602 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1603 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Power Lumbar Seats ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1604 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1605 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1606 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Rear Anti-Lock Brakes System ^ Programmable Speedometer/Odometer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1607 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1608 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1609 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1610 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1611 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Warning Indicators ^ Warning Chime Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1612 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1613 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1614 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1615 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1616 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations The interior fuse panel is located on a mounting bracket under the instrument panel, left of the steering column. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1622 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1623 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1624 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1625 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1626 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1627 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1628 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1629 Fuse Block: Electrical Diagrams Interior Fuse Panel Circuit-to-Fuse Cross Reference 4 Wheel Anti-Lock Brakes System Relay ........................................................................................................................................................... Fuse U & V Auxiliary A/C-Heater ......................................................................................................... ......................................................................................... Fuse A Blower Motor Relay ....................... .............................................................................................................................................................. ............... Fuse F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1630 Class I Trailer Running Lamps ............................................................................................................ ........................................................................ Fuse P Class II Trailer Running Lamps Relay ............ ............................................................................................................................................................ Fuse P Daytime Running Lamps Module ............................................................................................ ................................................................................... Fuse R Electronic Brake .................................. .............................................................................................................................................................. ......... Fuse D Fuse 1 ........................................................................................................................... ............................................................................................... Fuse S Fuse 10 ................................... .............................................................................................................................................................. ....................... Fuse F Fuse 12 ........................................................................................................... ............................................................................................................. Fuse S Fuse 15 ..................... .............................................................................................................................................................. ..................................... Fuse G Fuse 16 ............................................................................................. ........................................................................................................................... Fuse S Fuse 4 ......... .............................................................................................................................................................. ................................................... Fuse S Fuse 8 ................................................................................. ......................................................................................................................................... Fuse S Fuse R ................................................................................................................................................. ......................................................................... Fuse S Heated Oxygen Sensor ................................. .............................................................................................................................................................. . Fuse G Hood Lamp ........................................................................................................................... ...................................................................................... Fuse R Horn Relay ....................................... .............................................................................................................................................................. ............. Fuse R Ignition Switch ........................................................................................................... ................................................................................................. Fuse G Ignition System ..................... .............................................................................................................................................................. ........................ Fuse U Instrument Cluster .......................................................................................... ............................................................................................................. Fuse U Main Light Switch ...... .............................................................................................................................................................. ................................... Fuse S Modified Vehicle Power ....................................................................... ................................................................................................................ Fuse B & J PCM Power Relay ................................................................................................................................................... ................................................... Fuse U Plug-in Diode ...................................................................... ........................................................................................................................................ Fuse L Power Lumbar Seats ........................................................................................................................... ......................................................................... Fuse E Power Seats .................................................. .............................................................................................................................................................. . Fuse E Remote Keyless Entry Module .............................................................................................. ..................................................................................... Fuse A Trailer Adapter Battery Feed ............. .............................................................................................................................................................. ............ Fuse J Trailer Backup Lamp Relay ........................................................................................ ................................................................................................ Fuse K Trailer Battery Charge Relay .. .............................................................................................................................................................. ....................... Fuse J Trailer LH Turn/Stop Lamp .............................................................................. .......................................................................................................... Fuse N Trailer RH Turn/Stop Lamp .................................................................................................................................................... ................................... Fuse M Trailer Running Lamp Relay ............................................................... ....................................................................................................................... Fuse K Fuse A Fuse A - protects the following circuits: ^ Auxiliary A/C-Heater ^ Remote Keyless Entry Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1631 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1632 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1633 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1634 Power Distribution Fuse B Fuse B - protects the following circuits: ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1635 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1636 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1637 Power Distribution Fuse D Fuse D - protects the following circuits: ^ Electronic Brake Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1638 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1639 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1640 Power Distribution Fuse E Fuse E - protects the following circuits: ^ Power Seats ^ Power Lumbar Seats Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1641 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1642 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1643 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1644 Power Distribution Fuse F Fuse F - protects the following circuits: ^ Blower Motor Relay ^ Fuse 10 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1645 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1646 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1647 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1648 Power Distribution Fuse G Fuse G - protects the following circuits: ^ Ignition Switch ^ Fuse 15 ^ Heated Oxygen Sensor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1649 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1650 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1651 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1652 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1653 Power Distribution Fuse J Fuse J - protects the following circuits: ^ Trailer Battery Charge Relay ^ Trailer Adapter Battery Feed ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1654 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1655 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1656 Power Distribution Fuse K Fuse K - protects the following circuits: ^ Trailer Backup Lamp Relay ^ Trailer Running Lamp Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1657 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1658 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1659 Power Distribution Fuse M Fuse M - protects the following circuits: ^ Trailer RH Turn/Stop Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1660 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1661 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1662 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1663 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1664 Power Distribution Fuse N Fuse N - protects the following circuits: ^ Trailer LH Turn/Stop Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1665 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1666 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1667 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1668 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1669 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1670 Power Distribution Fuse P Fuse P - protects the following circuits: ^ Class I Trailer Running Lamps ^ Class II Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1671 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1672 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1673 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1674 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1675 Power Distribution Fuse S Fuse S - protects the following circuits: ^ Fuse 1 ^ Fuse 4 ^ Fuse 8 ^ Fuse 12 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1676 ^ Fuse 16 ^ Fuse R ^ Main Light Switch Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1677 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1678 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1679 Power Distribution Fuse U Fuse U - protects the following circuits: ^ Ignition System ^ Instrument Cluster ^ Part In Assembly Engine ^ PCM Power Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1680 ^ 4 Wheel Anti-Lock Brakes System Relay Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1681 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1682 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1683 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1684 Power Distribution Fuse V Fuse V - protects the following circuits: ^ 4 Wheel Anti-Lock Brakes System Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1685 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1686 Power Distribution Circuit-to-Circuit Breaker Cross Reference Anti-Theft Module ................................................................................................................................ .................................................... Circuit Breaker 12 Memory Lock Module ....................................... ....................................................................................................................................... Circuit Breaker 12 Power Door Locks ............................................................................................................. ....................................................................... Circuit Breaker 12 Power Windows ............................. ........................................................................................................................................................... Circuit Breaker 14 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1687 Circuit Breaker 12 Circuit Breaker 12 - protects the following circuits: ^ Anti-Theft Module ^ Power Door Locks ^ Memory Lock Module Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1688 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1689 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1690 Power Distribution Circuit Breaker 14 Circuit Breaker 14 - protects the following circuits: ^ Power Windows Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1691 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1692 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1693 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1694 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1695 Power Distribution Circuit-to-Fuse Cross Reference Accessory Tap ..................................................................................................................................... ........................................................................ Fuse 6 Air Bag Module ............................................... ................................................................................................................................................... Fuse 5 & 15 Anti-Theft Indicator ................................................................................................................... .................................................................................. Fuse 8 Anti-Theft Module ................................. .............................................................................................................................................................. . Fuse 6 & 7 Auxiliary Battery Relay .................................................................................................... ........................................................................................... Fuse 5 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1696 Backup Lamps ..................................................................................................................................... ........................................................................ Fuse 5 Blend Door Actuator ....................................... ............................................................................................................................................................ Fuse 9 Brake Pressure Switch ............................................................................................................ ..................................................................................... Fuse 1 Cigar Lighter ...................................... .............................................................................................................................................................. .......... Fuse 10 Courtesy Lamp Switch ................................................................................................ ................................................................................................. Fuse 8 Data Link Connector .............. .............................................................................................................................................................. ........................ Fuse 1 Daytime Running Lamps Module ................................................................... ............................................................................................................. Fuse 5 Dome/Map Lamp ....... .............................................................................................................................................................. .................................... Fuse 8 Flash to Pass ...................................................................................... .......................................................................................................................... Fuse 4 Function Selector Switch .................................................................................................................................... ......................................................... Fuse 9 Hazard Lamps ............................................................... ............................................................................................................................................... Fuse 5 Head and Park Lamp ........................................................................................................................... ........................................................................ Fuse 4 Illuminated Entry ............................................. ..................................................................................................................................................... Fuse 6 & 8 Instrument Illumination ............................................................................................................... ................................................................................. Fuse 4 Instrument Panel Illumination Lamps .... .............................................................................................................................................................. ...... Fuse 13 License Lamps ............................................................................................................... .............................................................................................. Fuse 4 Main Light Switch ..................... .............................................................................................................................................................. .................. Fuse 11 Modified Vehicle Power ...................................................................................... ...................................................................................................... Fuse 16 Park/Neutral Position Switch .................................................................................................................................................. ..................................... Fuse 7 Power Amplifier ................................................................................. ....................................................................................................................... Fuse 10 Power Lumbar Seats ................................................................................................................................................... ............................................... Fuse 16 Power Mirrors ........................................................................ ...................................................................................................................................... Fuse 8 Powertrain Control Module .................................................................................................................. ....................................................................... Fuse 7 Programmable Speedometer/Odometer Module ................................................................................................................................................. Fuse 1 & 17 Radio ............................................................................................................................... .......................................................................................... Fuse 11 Radio Memory ............................ .............................................................................................................................................................. ................... Fuse 8 Rear Anti-Lock Brakes System ............................................................................ ...................................................................................................... Fuse 17 Rear Power Outlet .......... .............................................................................................................................................................. .............................. Fuse 10 Remote Keyless Entry Module ............................................................... .............................................................................................................. Fuse 6 & 8 Shift Lock Actuator ............................................................................................................................................... ...................................................... Fuse 5 Speed Control ................................................................... .................................................................................................................................... Fuse 1 & 6 Trailer Battery Charge Relay ............................................................................................................... ........................................................................ Fuse 6 Transmission Control Switch .......................... ............................................................................................................................................................. Fuse 5 Transmission Range Sensor ................................................................................................... ...................................................................................... Fuse 7 Turn Lamps ...................................... .............................................................................................................................................................. .............. Fuse 5 Turn/Stop/Hazard Lamp ........................................................................................... ................................................................................................... Fuse 1 Visor Lamps ......................... .............................................................................................................................................................. ......................... Fuse 8 Warning Chime .............................................................................................. ............................................................................................................ Fuse 18 Warning Indicators .... .............................................................................................................................................................. .................................. Fuse 18 Windshield Wiper Motor ..................................................................... ........................................................................................................................ Fuse 2 Wiper Control Module ................................................................................................................................................. ................................................ Fuse 2 Fuse 1 Fuse 1 - protects the following circuits: ^ Turn/Stop/Hazard Lamp ^ Speed Control ^ Data Link Connector ^ Brake Pressure Switch ^ Programmable Speedometer/Odometer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1697 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1698 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1699 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1700 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1701 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Windshield Wiper Motor ^ Wiper Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1702 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1703 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1704 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1705 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ License Lamps ^ Flash to Pass ^ Instrument Illumination ^ Head and Park Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1706 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1707 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1708 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1709 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1710 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Air Bag Module ^ Daytime Running Lamps Module ^ Auxiliary Battery Relay ^ Shift Lock Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1711 ^ Transmission Control Switch ^ Backup Lamps ^ Turn Lamps ^ Hazard Lamps Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1712 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1713 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1714 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1715 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1716 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1717 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Speed Control ^ Remote Keyless Entry Module ^ Illuminated Entry ^ Accessory Tap Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1718 ^ Anti-Theft Module ^ Trailer Battery Charge Relay Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1719 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1720 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1721 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1722 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: ^ Anti-Theft Module ^ Transmission Range Sensor ^ Park/Neutral Position Switch ^ Powertrain Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1723 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1724 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1725 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1726 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1727 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Courtesy Lamp Switch ^ Illuminated Entry ^ Power Mirrors ^ Visor Lamps Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1728 ^ Anti-Theft Indicator ^ Radio Memory ^ Dome/Map Lamp ^ Remote Keyless Entry Module Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1729 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1730 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1731 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1732 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1733 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1734 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: ^ Function Selector Switch ^ Blend Door Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1735 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1736 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1737 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1738 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: ^ Cigar Lighter ^ Rear Power Outlet ^ Power Amplifier Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Radio ^ Main Light Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Instrument Panel Illumination Lamps Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1748 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1749 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1750 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1751 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1752 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Air Bag Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1753 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1754 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1755 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1756 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Power Lumbar Seats ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Rear Anti-Lock Brakes System ^ Programmable Speedometer/Odometer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Warning Indicators ^ Warning Chime Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1770 Fuse Block: Application and ID Fuses and Circuit Breakers Location and Values The following circuit protection charts give the location and values of all the circuits containing fuses or circuit breakers. Conventional Chassis Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1771 Fuse Panel, E-250 Commercial Chassis and E-350 RV Chassis Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations Fusible Link: Locations The fuseable links are located in the Power distribution box, on the lefthand fender apron. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions Fusible Link: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1777 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1778 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1779 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1780 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1781 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1782 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1783 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1784 Fusible Link: Electrical Diagrams Fuse Link A Fuse Link A - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1785 Fuse Link B Fuse Link B - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Power Distribution Fuse Link C Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1786 Fuse Link C - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Power Distribution Fuse Link D Fuse Link D - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1787 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1788 Power Distribution Fuse Link E Fuse Link E - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1789 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1790 Power Distribution Fuse Link F Fuse Link F - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1791 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1792 Power Distribution Fuse Link G Fuse Link G - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1793 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1794 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Box: Locations Location An engine compartment power distribution box is located near the lower left-hand fender apron. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp - A/T > Component Information > Description and Operation Malfunction Indicator Lamp - A/T: Description and Operation Transmission Control Indicator (TCIL) DESCRIPTION Indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation PURPOSE To alert the vehicle operator that the engine oil level is low. COMPONENTS The system consists of a float-type sensor mounted to the side of the engine oil pan, an electronic control module, and an instrument panel warning lamp. OPERATION The Check Oil Indicator will light with ignition switch in the START position as a bulb prove-out. When ignition switch is turned to RUN or START position, the control module determines whether sensor is grounded (oil low) or ungrounded (oil not low). If oil level is adequate, light will go out in RUN. If oil level is approximately 1.5 quarts or more low, the relay turns the warning lamp ON. The lamp will remain ON until ignition is turned OFF. After ignition is turned OFF, module will not reset for approximately five minutes. This delay allows time for oil drain back before another reading is allowed to occur. If engine is restarted during this delay period, the last reading will be displayed. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Description and Operation > Page 1805 Oil Level Warning Indicator: Testing and Inspection With oil level at FULL mark on oil dipstick and engine oil warm to assure that oil drains properly from oil sensor, turn ignition ON and start engine. Warning lamp should come on briefly in START for bulb test, then go out. Turn engine OFF. Drain two quarts of oil from engine. Wait approximately five minutes, then restart engine. Warning lamp should come on and stay on. If warning lamp does not come on check fuse, low oil level relay, low oil level sensor and lamp. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1811 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1812 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1813 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1814 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1815 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1816 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1817 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1818 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1819 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1820 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1821 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1822 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1823 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1824 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1825 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1826 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1827 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1828 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1829 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1830 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1831 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1832 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1833 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1834 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1835 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1836 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1837 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1838 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1839 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1840 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1841 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1842 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1843 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1844 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1845 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1846 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1847 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1848 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1849 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1850 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1851 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1852 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1853 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1854 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1855 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1856 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1857 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1858 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1859 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1860 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1861 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1862 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1863 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1864 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1865 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1866 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1867 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1868 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1869 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1870 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1871 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1872 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1873 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1874 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1875 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1876 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1877 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1878 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1879 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1880 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1881 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1882 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1883 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1884 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1885 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1886 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1887 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1888 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1889 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1890 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1891 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1892 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1893 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1894 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1895 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1896 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1897 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1898 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1899 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1900 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1901 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1902 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1903 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1904 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1905 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1910 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1911 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1912 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1913 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1914 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1915 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1916 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1917 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1918 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1919 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1920 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1921 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1922 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1923 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1924 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1925 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1926 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1927 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1928 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1929 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1930 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1931 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1932 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1933 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1934 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive 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Noise/Vibration/Harshness Procedure > Page 1955 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1956 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1957 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1958 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1959 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1960 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1961 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1962 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1963 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1964 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1965 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1966 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1967 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1968 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1969 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1970 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1971 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1972 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1973 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1974 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1975 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1976 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1977 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1978 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1979 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1980 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1981 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1982 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1983 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1984 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1985 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1986 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1987 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1988 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1989 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1990 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1991 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1992 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1993 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1995 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1996 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1997 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1998 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1999 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2000 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2001 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2002 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2003 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2004 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2005 Wheels: Specifications 5 LUG WHEEL 1/2-20 .................................................................................................................................................. ........................................... 135 Nm (100 lb ft) 8 LUG WHEEL 9/16-18 ................................................................................................................................................ ........................................... 190 Nm (140 lb ft) NOTE: Torque specifications are for clean, dirt and paint free dry bolt and nut threads. Never use oil or grease on studs and nuts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2010 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2011 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2012 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2013 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2014 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2015 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2016 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2017 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2018 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2019 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2020 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2021 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2022 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2023 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2024 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2025 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2026 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2027 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2028 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2029 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2030 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2031 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2032 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2033 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2034 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2035 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2036 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2037 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2038 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2039 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2040 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2041 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2042 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2043 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2044 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2045 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2046 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2047 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2048 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2049 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2050 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2051 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2052 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2053 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2054 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2055 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2056 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2057 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2058 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2059 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2060 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2061 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2062 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2063 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2064 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2065 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2066 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2067 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2068 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2069 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2070 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2071 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2072 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2073 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2074 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2075 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2076 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2077 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2078 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2079 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2080 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2081 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2082 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2083 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2084 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2085 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2086 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2087 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2088 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2089 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2090 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2091 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2092 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2093 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2094 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2095 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2096 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2097 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2098 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2099 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2100 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2101 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2102 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2103 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2104 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 2105 Wheel Bearing: Specifications Wheel Bearing Adjusting Nut [1] ...................................................................................................................................................... 23-34 Nm (17-25 ft lb) Bearing End Play ............................................................................................. .................................................................. 0.006-0.127mm (.00025-.005 in) Hub and Rotor Rotation Torque ................................................................................................................................................. 1.13-2.82 Nm (10-25 in lb) [1] Back nut off approximately one half turn. Tighten nut to 2.03-2.26 Nm (18-20 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments > Front Wheel Bearing: Adjustments Front 1. Raise the vehicle until the tire clears the floor and install safety stands. 2. Remove the wheel cover or hub cap, if so equipped. 3. Using a suitable tool, remove the grease cap from the hub. Wipe the excess grease from the end of the spindle. Remove the cotter pin and locknut. 4. Loosen the adjusting nut three turns. Attempt to obtain running clearance between the rotor brake surface and the disc pads by rocking the wheel, hub and rotor assembly in and out several times to push the pads away from the rotor. NOTE: Do not pry on the caliper phenolic piston. 5. If running clearance cannot be maintained throughout bearing adjustment in Steps 5 and 6, the caliper must be removed. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 6. Tighten wheel bearing adjusting nut to 23-34 Nm (17-25 ft lb) while rotating the disc brake rotor in the opposite direction. 7. Back nut off approximately one half turn. 8. Tighten nut to 2.03-2.26 Nm (18-20 in lb) while rotating the disc brake rotor. ^ End play should be 0.006-0.127mm (.00025-.005 in). ^ Torque required to rotate the hub should be 1.13-2.82 Nm (10-25 in lb). 9. Install the retainer and new cotter pin bending both ends of cotter pin around retainer. Install grease cap. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments > Front > Page 2108 Wheel Bearing: Adjustments Rear REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove axle shaft bolts. 5. Using suitable dolly, raise wheel until all weight is removed from wheel bearings. 6. Remove brake drum. 7. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 8. Remove outer bearing, then pull wheel assembly from axle. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. Check for proper seating of bearing cup by trying to insert a 0.0015 in feeler gauge between cups and wheel hub. The gauge should not enter beneath cup. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 15. Install outer wheel bearing and start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 65-75 ft lb Rotate hub occasionally while tightening to set bearings. After torquing to specifications, ratchet back 90°, then torque to 15-20 ft lb. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL AND INSTALLATION 1. Raise and support front of vehicle and remove front wheels. 2. Remove brake caliper and position aside, leaving brake lines attached. CAUTION: 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. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2111 Wheel Bearing: Service and Repair Rear REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove wheel assembly, then remove brake drum. 5. Remove axle shaft bolts. 6. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 7. Install Step Plate Adapter tool No. D80L-630-7 and Puller tool No. D80L-1002-L, or equivalents. Loosen hub until it can be removed. 8. Remove hub, then outer bearing. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Install outer wheel bearing into hub, then slide hub assembly onto axle housing spindle. 15. Start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 55-65 ft lb. Rotate hub occasionally while tightening, to set bearings. After torquing to specifications, ratchet back five clicks (1/8 turn) for new bearing or eight clicks (1/6 turn) for used bearings. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb and tighten axle shaft retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 96114 > May > 96 > Center Wheel Ornament - Falls Off Wheel Cover: Customer Interest Center Wheel Ornament - Falls Off Article No. 96-11-4 05/20/96 ^ TRIM - EXTERIOR - CENTER WHEEL ORNAMENT FALLING OFF - VEHICLES BUILT THROUGH 12/8/95 WITH 16 INCH WHEELS ^ WHEELS - CENTER WHEEL ORNAMENT FALLING OFF - VEHICLES BUILT THROUGH 12/8/95 WITH 16 INCH WHEELS LIGHT TRUCK: 1995-96 E-25O, E-35O, F-25O, F-350 ISSUE: The center wheel ornament may fall off of the wheel(s) while driving. This may be caused by broken retention clips, poor clip retention and/or improper installation. ACTION: Remove any existing center wheel ornaments and replace all four (4) of the center wheel ornaments using the wheel ornament kit. The new ornaments have improved clip retention and an easier installation procedure to reduce the possibility of improper installation. Make sure the ornament is centered and pressed on evenly around the outside edge with both hands. Do not hit the ornament to install it as this may damage the ornament. PART NUMBER PART NAME F5UZ-1A108-VB Wheel Ornament Kit (E-250 SRW With Semi-Float Axle) F5TZ-1A108-XB Wheel Ornament Kit (E/F-250-35O 4X2 With Full-Float Axle) F5TZ-1A108-UB Wheel Ornament Kit (F-250/350 4X4 SRW) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961104A Replace Wheel Ornaments 0.4 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1130 02 OASIS CODES: 108000, 306000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 96114 > May > 96 > Center Wheel Ornament - Falls Off Wheel Cover: All Technical Service Bulletins Center Wheel Ornament - Falls Off Article No. 96-11-4 05/20/96 ^ TRIM - EXTERIOR - CENTER WHEEL ORNAMENT FALLING OFF - VEHICLES BUILT THROUGH 12/8/95 WITH 16 INCH WHEELS ^ WHEELS - CENTER WHEEL ORNAMENT FALLING OFF - VEHICLES BUILT THROUGH 12/8/95 WITH 16 INCH WHEELS LIGHT TRUCK: 1995-96 E-25O, E-35O, F-25O, F-350 ISSUE: The center wheel ornament may fall off of the wheel(s) while driving. This may be caused by broken retention clips, poor clip retention and/or improper installation. ACTION: Remove any existing center wheel ornaments and replace all four (4) of the center wheel ornaments using the wheel ornament kit. The new ornaments have improved clip retention and an easier installation procedure to reduce the possibility of improper installation. Make sure the ornament is centered and pressed on evenly around the outside edge with both hands. Do not hit the ornament to install it as this may damage the ornament. PART NUMBER PART NAME F5UZ-1A108-VB Wheel Ornament Kit (E-250 SRW With Semi-Float Axle) F5TZ-1A108-XB Wheel Ornament Kit (E/F-250-35O 4X2 With Full-Float Axle) F5TZ-1A108-UB Wheel Ornament Kit (F-250/350 4X4 SRW) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961104A Replace Wheel Ornaments 0.4 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1130 02 OASIS CODES: 108000, 306000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle Wheel Hub: Service and Repair Dana/Spicer Integral Housing Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove axle shaft bolts. 5. Using suitable dolly, raise wheel until all weight is removed from wheel bearings. 6. Remove brake drum. 7. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 8. Remove outer bearing, then pull wheel assembly from axle. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. Check for proper seating of bearing cup by trying to insert a 0.0015 in feeler gauge between cups and wheel hub. The gauge should not enter beneath cup. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 15. Install outer wheel bearing and start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 65-75 ft lb Rotate hub occasionally while tightening to set bearings. After torquing to specifications, ratchet back 90°, then torque to 15-20 ft lb. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle > Page 2129 Wheel Hub: Service and Repair Ford Integral Carrier Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove wheel assembly, then remove brake drum. 5. Remove axle shaft bolts. 6. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 7. Install Step Plate Adapter tool No. D80L-630-7 and Puller tool No. D80L-1002-L, or equivalents. Loosen hub until it can be removed. 8. Remove hub, then outer bearing. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Install outer wheel bearing into hub, then slide hub assembly onto axle housing spindle. 15. Start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 55-65 ft lb Rotate hub occasionally while tightening, to set bearings. After torquing to specifications, ratchet back five clicks (1/8 turn) for new bearing or eight clicks (1/6 turn) for used bearings. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb and tighten axle shaft retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 2134 ^ 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 2135 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 2136 Wheel Fastener: Specifications Wheel Lug Torque 9/16-18 ................................................................................................................................................ ........................................... 190 Nm (140 lb ft) NOTE: Torque specifications are for clean, dirt and paint free dry bolt and nut threads. Never use oil or grease on studs and nuts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle Wheel Seal: Service and Repair Dana/Spicer Integral Housing Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove axle shaft bolts. 5. Using suitable dolly, raise wheel until all weight is removed from wheel bearings. 6. Remove brake drum. 7. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 8. Remove outer bearing, then pull wheel assembly from axle. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. Check for proper seating of bearing cup by trying to insert a 0.0015 in feeler gauge between cups and wheel hub. The gauge should not enter beneath cup. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 15. Install outer wheel bearing and start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 65-75 ft lb. Rotate hub occasionally while tightening to set bearings. After torquing to specifications, ratchet back 90°, then torque to 15-20 ft lb. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle > Page 2141 Wheel Seal: Service and Repair Ford Integral Carrier Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove wheel assembly, then remove brake drum. 5. Remove axle shaft bolts. 6. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 7. Install Step Plate Adapter tool No. D80L-630-7 and Puller tool No. D80L-1002-L, or equivalents. Loosen hub until it can be removed. 8. Remove hub, then outer bearing. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Install outer wheel bearing into hub, then slide hub assembly onto axle housing spindle. 15. Start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 55-65 ft lb. Rotate hub occasionally while tightening, to set bearings. After torquing to specifications, ratchet back five clicks (1/8 turn) for new bearing or eight clicks (1/6 turn) for used bearings. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb and tighten axle shaft retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Behind RVs Guidelines Towing Information: Technical Service Bulletins Vehicle - Towing Behind RVs Guidelines Article No. 98-5A-12 03/18/98 ^ BRAKES - WEIGHT LIMITATIONS FOR TOWING ^ RECREATIONAL VEHICLES - WEIGHT RATINGS FOR UNBRAKED TOWING LESS THAN GROSS COMBINATION WEIGHT RATING (GCWR) ^ TOWING BEHIND RECREATIONAL VEHICLES - RECOMMENDED GUIDELINES ^ TRANSAXLE/TRANSMISSION/TRANSFER CASE - VEHICLES TOWED BEHIND RECREATIONAL VEHICLES - RECOMMENDED TOWING GUIDELINES FORD: 1988-93 FESTIVA 1988-94 TEMPO 1989-96 PROBE, TAURUS SHO 1991-97 ESCORT 1994-96 ASPIRE LINCOLN-MERCURY: 1988-94 TOPAZ 1991-94 CAPRI 1991-97 TRACER LIGHT TRUCK: 1988-96 AEROSTAR, BRONCO, E-350, F SUPER DUTY, F-250, F-350, F-53 MOTORHOME, RANGER 1988-97 F-150 1991-96 EXPLORER 1997 MOUNTAINEER ISSUE: Many motorhome owners tow a vehicle when traveling. Improper techniques can "overload" the brake system of the tow vehicle or damage the drivetrain of the vehicle being towed. ACTION: Use the information and charts shown in this TSB article to properly match tow vehicle, towed vehicle and towing method. TOWING METHODS 1. TRAILER - The vehicle is loaded onto and secured to a trailer and simply acts as "secured" cargo. 2. DOLLY - The vehicle is "partially" loaded and partially towed. Either front or rear wheels are loaded and secured to a "towing dolly" and the other wheels roll on the road. 3. TOW BAR - All of the vehicle wheels roll on the pavement. The towed vehicle's steering column must be unlocked so that it can track correctly behind the tow vehicle. WEIGHT RATINGS AND BRAKES ^ GVWR (Gross Vehicle Weight Rating) - is the MAXIMUM allowable weight of the towing vehicle, passengers and cargo ^ GCWR (Gross Combined Weight Rating) - is the MAXIMUM allowable weight of the towing vehicle and the weight of the trailer or vehicle being towed, including all passengers and cargo ^ BRAKES - The motorhome brakes are designed and rated for the GVWR of that vehicle and will provide adequate braking for trailers and towing vehicles up to 680 kg (1500 lb) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Behind RVs Guidelines > Page 2146 CAUTION: SEPARATE AUXILIARY BRAKES ARE REQUIRED ON TRAILERS OR TOWED VEHICLES OVER 680 KG (1500 LBS). DO NOT CONNECT A TRAILER'S, DOLLY'S OR OTHER TOWED VEHICLE'S BRAKE SYSTEM TO THE TOWING VEHICLE'S BRAKE SYSTEM. TOWED VEHICLES 1. Trailer-towed - The vehicle should be loaded on the trailer in a manner to: a. achieve a trailer tongue load of 10-15% of total trailer weight, b. not exceed the trailer or hitch ratings and c. be securely tied down. 2. Dolly-towed - For front wheel drive vehicles, towing an automatic transaxle (ATX)-equipped vehicle behind another vehicle, such as a Recreational Vehicle (RV), requires that a front wheel dolly or trailer be used. NOTE: TEMPO ALL-WHEEL DRIVE MODELS MUST BE TRAILER-TOWED. DO NOT TOW THESE VEHICLES USING A TWO-WHEEL TOWING DOLLY. CAUTION: DO NOT TOW A VEHICLE WITH AN AUTOMATIC (ATX) TRANSAXLE WITH THE DRIVE WHEELS ON THE GROUND. DAMAGE TO THE TRANSAXLE MAY RESULT. 3. Tow Bar-towed - Vehicles which can be successfully towed with a tow bar are listed in the following chart. Additional vehicle-specific information follows the chart. ALL VEHICLES NOTE: DO NOT TOW ANY VEHICLE AT A SPEED FASTER THAN 88 KM/H (55 MPH). THE MAXIMUM TOWING DISTANCE (WHEN TOWED CORRECTLY) IS UNLIMITED. WARNING: NEVER USE A TOW BAR THAT ATTACHES ONLY TO THE BUMPER. MTX-EQUIPPED VEHICLES Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Behind RVs Guidelines > Page 2147 Towing a manual transaxle (MTX)-equipped vehicle with the drive wheels on the ground is acceptable only if the vehicle is towed in a forward direction. The parking brake must be released and the gear shift lever must be in Neutral. ^ For Aspire, Festiva, Escort and Tracer, the ignition key must be in the ACO position, the battery must be disconnected to eliminate battery drain, and the steering wheel must be unlocked ^ For Capri, the ignition key must be in the OFF position and the steering wheel unlocked ^ Refer to the specific vehicle Owner Guide for complete details CAUTION: TOWING MTX-EQUIPPED VEHICLES INCORRECTLY MAY RESULT IN TRANSAXLE DAMAGE. TRUCKS ^ The steering wheel must be unlocked by placing the ignition key in the OFF position ^ Manual transmission shift lever must be in Neutral ^ On 4X4 manual shift transfer cases, the shift lever must be in Neutral ^ 4X4 locking hubs (both manual and automatic) must be unlocked ^ Refer to the specific vehicle Owner Guide for complete details OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-24-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression pressures are considered within specification if they are at least 350 psi and the lowest reading cylinder is within 50 psi of the highest. NOTE: Variations exceeding specifications indicate an improperly seated valve or worn/broken piston rings. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2153 Compression Check: Testing and Inspection 1. Warm engine to normal operating temperature, then turn ignition off. 2. Remove the alternator retaining bolt and electrical connectors and and position aside. 3. Remove drive belt. 4. Remove the alternator bracket retaining bolts. 5. Remove the alternator with the bracket attached. 6. Remove the dipstick assembly and bracket. 7. Remove the fuel injector wiring harness connector from the valve cover gasket. 8. Remove valve covers. 9. Unplug harness from the glow plugs and remove all glow plugs. 10. Install suitable compression gauge into cylinder No. 1 glow plug hole. 11. Crank engine at least five compression strokes with ignition switch off. Record highest reading indicated. 12. Repeat compression check on each cylinder. 13. Compression pressures are considered within specification if they are at least 350 psi and the lowest reading cylinder is within 50 psi of the highest. 14. Variations exceeding specifications indicate an improperly seated valve or worn/broken piston rings. 15. Reverse procedure to reassemble after tests. CAUTION: Do not add oil to cylinder as this may cause hydrostatic lock. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Fig. 12 Exploded View Of Valve Lifter 1. Disassemble valve lifter, then clean all parts in solvent and wipe dry. 2. If any parts of lifter are worn or damaged, or plunger is not free in body, replace entire assembly. 3. Check that roller rotates freely and is not worn or damaged. 4. Lubricate all components with clean engine oil, then assemble. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Left Side Push Rod: Service and Repair Left Side REMOVAL 1. Disconnect both battery ground cables (14301). Air Cleaner Assembly 2. Remove air cleaner assembly. 3. Discharge A/C system. 4. Disconnect electrical connectors from A/C system. 5. Disconnect manifold lines from A/C compressor. 6. Remove the four A/C compressor mounting bracket retaining bolts and remove the A/C compressor mounting bracket (2882) (with A/C attached). 7. Remove the interior engine cover. 8. Remove the intake duct tube assembly bolts and the clamps at the air cleaner. Remove the air inlet duct tube assembly. 9. Remove the oil fill tube. 10. Remove the intake duct bracket and retaining nuts. 11. Remove the crankcase breather screws and the breather assembly. 12. Remove the valve cover bolts. 13. Remove the valve cover. 14. Disconnect the electrical connectors from the fuel injectors and glow plugs. 15. Remove the valve cover gasket. 16. Remove the two rocker arm bolts (6A527) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Left Side > Page 2162 Rocker Arm Assembly 17. Remove the rocker arm (6564) assembly. 18. Remove the push rod (6565). NOTE: Be careful when removing the rocker arm snap retaining clip. Do not lose the rocker arm steel ball. 19. Remove the snap retaining clip. 20. Remove the rocker arm and steel ball from the rocker arm pedestal. INSTALLATION 1. Assemble the intake rocker arm or exhaust rocker arm assembly as follows: a. Place the steel ball in the rocker arm cup and lubricate it with clean engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Left Side > Page 2163 b. Place the rocker arm pedestal on the steel ball. Rocker Arm Cutaway View c. Snap the retaining clip over the rocker arm pedestal groove. 2. Lubricate the push rod ends with engine oil and install the push rod (copper end up). CAUTION: Failure to follow the next step of this procedure could result in bent valves. 3. Rotate the engine until the mark on the crankshaft damper is at 11 O'clock to prevent valve damage when installing the intake rocker arm and exhaust rocker arm. 4. Install the intake rocker arm or exhaust rocker arm. 5. Install the two rocker arm bolts. Tighten rocker arm bolts evenly to 27 Nm (20 ft lb). 6. Install the valve cover gasket. Fuel Injector Connector 7. Connect the electrical connectors to the fuel injectors and glow plugs. 8. Install the valve cover and retaining bolts. Tighten bolts to 11 Nm (8 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Left Side > Page 2164 9. Connect the engine harness electrical connectors to the valve cover gasket. Install the fuel injector harness clip. 10. Install the wiring harness retainer at the valve cover. 11. Install the tube mounting bracket and retaining nuts. Install the rear nut from inside the vehicle and install the front nut from outside the vehicle. 12. Install the engine oil level indicator tube retaining screw at the tube mounting bracket. 13. Install the alternator and the alternator retaining bolts. Tighten bolts to 40-55 Nm (30-40 ft lb). 14. Install the drive belt. 15. Connect the alternator electrical connectors. 16. Install air cleaner assembly. 17. Connect negative battery cables. 18. Start engine and check for leaks. 19. Install the interior engine cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Left Side > Page 2165 Push Rod: Service and Repair Right Side REMOVAL 1. Disconnect both battery negative cables. 2. Remove air cleaner assembly. 3. Disconnect the alternator electrical connectors. 4. Remove the drive belt (8620). 5. Remove the alternator retaining bolts and the alternator (10300). 6. Remove the engine oil level indicator tube retaining screw at the tube mounting bracket. 7. Remove the interior engine cover. 8. Remove the tube mounting bracket retaining nuts and tube mounting bracket at the valve cover (6582). Remove the rear nut from inside the vehicle and remove the front nut from outside the vehicle. 9. Position the engine wiring harnesses aside. 10. Remove the wiring harness retainer at valve cover. WARNING: RED-STRIPED WIRES CARRY 115 VDC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. Engine Harness View 11. Remove the fuel injector harness clip, and disconnect the engine harness electrical connectors from the valve cover gasket (6584). 12. Remove the valve cover bolts and valve cover from inside of the vehicle. 13. Disconnect the electrical connectors from the fuel injectors and glow plugs. 14. Remove the valve cover gasket. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Left Side > Page 2166 Rocker Arm Assembly 15. Remove the two rocker arm bolts (6A527). 16. Remove the rocker arm (6564) assembly. 17. Remove the push rod (6565). NOTE: Be careful when removing the rocker arm snap retaining clip. Do not lose the rocker arm steel ball. 18. Remove the snap retaining clip. 19. Remove the rocker arm and steel ball from the rocker arm pedestal. INSTALLATION 1. Assemble the intake rocker arm or rocker arm assembly as follows: a. Place the steel ball in the rocker arm cup and lubricate it with clean engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Left Side > Page 2167 b. Place the rocker arm pedestal on the steel ball. Rocker Arm Cutaway View c. Snap the retaining clip over the rocker arm pedestal groove. 2. Lubricate the push rod ends with engine oil and install the push rod (copper end up). CAUTION: Failure to follow the next step of this procedure could result in bent valves. 3. Rotate the engine until the mark on the crankshaft damper is at 11 O'clock to prevent valve damage when installing the intake rocker arm and exhaust rocker arm. 4. Install the intake rocker arm or exhaust rocker arm. 5. Install the two rocker arm bolts. Tighten rocker arm bolts evenly to 27 Nm (20 ft lb). 6. Install the valve cover gasket. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Left Side > Page 2168 Fuel Injector Connector 7. Connect the electrical connectors to the fuel injectors and glow plugs. 8. Install the valve cover and retaining bolts. Tighten bolts to 11 Nm (8 ft lb). 9. Connect the engine harness electrical connectors to the valve cover gasket. Install the fuel injector harness clip. 10. Install the wiring harness retainer at the valve cover. 11. Install the tube mounting bracket and retaining nuts. Install the rear nut from inside the vehicle and install the front nut from outside the vehicle. 12. Install the engine oil level indicator tube retaining screw at the tube mounting bracket. 13. Install the alternator and the alternator retaining bolts. Tighten bolts to 40-55 Nm (30-40 ft lb). 14. Install the drive belt. 15. Connect the alternator electrical connectors. 16. Install air cleaner assembly. 17. Connect negative battery cables. 18. Start engine and check for leaks. 19. Install the interior engine cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Left Side Rocker Arm Assembly: Service and Repair Left Side LEFT SIDE REMOVAL 1. Disconnect battery ground cables (14301). Air Cleaner Assembly 2. Remove air cleaner assembly. 3. Discharge A/C system. 4. Disconnect electrical connectors from A/C system. 5. Disconnect manifold lines from A/C compressor. 6. Remove the four A/C compressor mounting bracket retaining bolts and remove the A/C compressor mounting bracket (2882) (with A/C attached). 7. Remove the interior engine cover. 8. Remove the intake duct tube assembly bolts and the clamps at the air cleaner. Remove the air inlet duct tube assembly. 9. Remove the oil fill tube. 10. Remove the intake duct bracket and retaining nuts. 11. Remove the crankcase breather screws and the breather assembly. 12. Remove the valve cover bolts. 13. Remove the valve cover. WARNING: RED-STRIPED WIRES CARRY 115 VDC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. 14. Disconnect the electrical connectors from the fuel injectors and glow plugs. 15. Remove the valve cover gasket. 16. Remove the two rocker arm bolts (6A527) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2173 Rocker Arm Assembly 17. Remove the rocker arm (6564) assembly. 18. Remove the push rod (6565). NOTE: Be careful when removing the rocker arm snap retaining clip. Do not lose the rocker arm steel ball. 19. Remove the snap retaining clip. 20. Remove the rocker arm and steel ball from the rocker arm pedestal. INSTALLATION 1. Assemble the intake rocker arm or exhaust rocker arm assembly as follows: a. Place the steel ball in the rocker arm cup and lubricate it with clean engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2174 b. Place the rocker arm pedestal on the steel ball. Rocker Arm Cutaway View c. Snap the retaining clip over the rocker arm pedestal groove. 2. Lubricate the push rod ends with engine oil and install the push rod (copper end up). CAUTION: Failure to follow the next step of this procedure could result in bent valves. 3. Rotate the engine until the mark on the crankshaft damper is at 11 O'clock to prevent valve damage when installing the intake rocker arm and exhaust rocker arm. 4. Install the intake rocker arm or exhaust rocker arm. 5. Install the two rocker arm bolts. Tighten rocker arm bolts evenly to 27 Nm (20 ft lb). 6. Install the valve cover gasket. Fuel Injector Connector 7. Connect the electrical connectors to the fuel injectors and glow plugs. 8. Install the valve cover and retaining bolts. Tighten bolts to 11 Nm (8 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2175 9. Connect the engine harness electrical connectors to the valve cover gasket. Install the fuel injector harness clip. 10. Install the wiring harness retainer at the valve cover. 11. Install the tube mounting bracket and retaining nuts. Install the rear nut from inside the vehicle and install the front nut from outside the vehicle. 12. Install the engine oil level indicator tube retaining screw at the tube mounting bracket. 13. Install the alternator and the alternator retaining bolts. Tighten bolts to 40-55 Nm (30-40 ft lb). 14. Install the drive belt. 15. Connect the alternator electrical connectors. 16. Install air cleaner assembly. 17. Connect negative battery cable. 18. Start engine and check for leaks. 19. Install the interior engine cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2176 Rocker Arm Assembly: Service and Repair Right Side Engine Harness View REMOVAL 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect the alternator electrical connectors. 4. Remove the drive belt (8620). 5. Remove the alternator retaining bolts and the alternator (10300). 6. Remove the engine oil level indicator tube retaining screw at the tube mounting bracket. 7. Remove the interior engine cover. 8. Remove the tube mounting bracket retaining nuts and tube mounting bracket at the valve cover (6582). Remove the rear nut from inside the vehicle and remove the front nut from outside the vehicle. 9. Position the engine wiring harnesses aside. 10. Remove the wiring harness retainer at valve cover. WARNING: RED-STRIPED WIRES CARRY 115 VDC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. 11. Remove the fuel injector harness clip, and disconnect the engine harness electrical connectors from the valve cover gasket (6584). 12. Remove the valve cover bolts and valve cover from inside of the vehicle. 13. Disconnect the electrical connectors from the fuel injectors and glow plugs. 14. Remove the valve cover gasket. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2177 Rocker Arm Assembly 15. Remove the two rocker arm bolts (6A527). 16. Remove the rocker arm (6564) assembly. 17. Remove the push rod (6565). NOTE: Be careful when removing the rocker arm snap retaining clip. Do not lose the rocker arm steel ball. 18. Remove the snap retaining clip. 19. Remove the rocker arm and steel ball from the rocker arm pedestal. INSTALLATION 1. Assemble the intake rocker arm or rocker arm assembly as follows: a. Place the steel ball in the rocker arm cup and lubricate it with clean engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2178 b. Place the rocker arm pedestal on the steel ball. Rocker Arm Cutaway View c. Snap the retaining clip over the rocker arm pedestal groove. 2. Lubricate the push rod ends with engine oil and install the push rod (copper end up). CAUTION: Failure to follow the next step of this procedure could result in bent valves. 3. Rotate the engine until the mark on the crankshaft damper is at 11 O'clock to prevent valve damage when installing the intake rocker arm and exhaust rocker arm. 4. Install the intake rocker arm or exhaust rocker arm. 5. Install the two rocker arm bolts. Tighten rocker arm bolts evenly to 27 Nm (20 ft lb). 6. Install the valve cover gasket. Fuel Injector Connector 7. Connect the electrical connectors to the fuel injectors and glow plugs. 8. Install the valve cover and retaining bolts. Tighten bolts to 11 Nm (8 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2179 9. Connect the engine harness electrical connectors to the valve cover gasket. Install the fuel injector harness clip. 10. Install the wiring harness retainer at the valve cover. 11. Install the tube mounting bracket and retaining nuts. Install the rear nut from inside the vehicle and install the front nut from outside the vehicle. 12. Install the engine oil level indicator tube retaining screw at the tube mounting bracket. 13. Install the alternator and the alternator retaining bolts. Tighten bolts to 40-55 Nm (30-40 ft lb). 14. Install the drive belt. 15. Connect the alternator electrical connectors. 16. Install air cleaner assembly. 17. Connect negative battery cable. 18. Start engine and check for leaks. 19. Install the interior engine cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Refer to Engine/Specifications/Mechanical for tightening torque. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair Crankshaft Gear/Sprocket: Service and Repair CAUTION: The crankshaft sprocket (6306) is not serviced separately from the crankshaft (6303). Do not attempt to remove the crankshaft sprocket or damage to the crankshaft and crankshaft sprocket will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Valley Cover > Component Information > Technical Service Bulletins > Customer Interest for Engine Valley Cover: > 03-21-21 > Oct > 03 > Engine - Oil Leak at Valley Pan/Oil Pump Engine Valley Cover: Customer Interest Engine - Oil Leak at Valley Pan/Oil Pump Article No. 03-21-21 10/06/03 LEAK - OIL LEAK AT ENGINE VALLEY PAN AND/OR HIGH PRESSURE OIL PUMP - VEHICLES EQUIPPED WITH 7.3L DIESEL ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-2-16 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A high number of high pressure Rexroth pumps and Injection Pressure Regulators (IPR) are being replaced due to oil leaking, when all that is required is a new gasket or seal on either the pump or IPR. ACTION If a suspected oil leak is being observed from either component, replace the pump gasket with new gaskets. Pump or IPR replacement is not appropriate for an oil leak. Any pumps and/or IPR's returned must have location of oil leak noted on the diagnostic form which must accompany the returned part. Refer to the appropriate Service Manual for specific details. NOTE HIGH PRESSURE PUMPS RETURNED FOR OIL LEAKS THAT ARE FOUND TO BE FUNCTIONING PROPERLY WILL BE RETURNED AND CHARGED BACK FOR WARRANTY. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-2-16 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Valley Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Valley Cover: > 03-21-21 > Oct > 03 > Engine - Oil Leak at Valley Pan/Oil Pump Engine Valley Cover: All Technical Service Bulletins Engine - Oil Leak at Valley Pan/Oil Pump Article No. 03-21-21 10/06/03 LEAK - OIL LEAK AT ENGINE VALLEY PAN AND/OR HIGH PRESSURE OIL PUMP - VEHICLES EQUIPPED WITH 7.3L DIESEL ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-2-16 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A high number of high pressure Rexroth pumps and Injection Pressure Regulators (IPR) are being replaced due to oil leaking, when all that is required is a new gasket or seal on either the pump or IPR. ACTION If a suspected oil leak is being observed from either component, replace the pump gasket with new gaskets. Pump or IPR replacement is not appropriate for an oil leak. Any pumps and/or IPR's returned must have location of oil leak noted on the diagnostic form which must accompany the returned part. Refer to the appropriate Service Manual for specific details. NOTE HIGH PRESSURE PUMPS RETURNED FOR OIL LEAKS THAT ARE FOUND TO BE FUNCTIONING PROPERLY WILL BE RETURNED AND CHARGED BACK FOR WARRANTY. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-2-16 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Locations Valve Clearance: Locations Front To Rear Left ....................................................................................................................................................... ........................................................ I-E-I-E-I-E-I-E Right .................................................................................................................................................... ......................................................... E-I-E-I-E-I-E-I Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Locations > Page 2204 Valve Clearance: Adjustments These engines use hydraulic lifters and there is no provision for adjustment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information Fuel Pressure Release: Customer Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information > Page 2209 Fuel Pressure Release: Technician Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2210 Fuel Pressure Release: Service and Repair 1. Remove fuel tank filler cap to relieve any pressure in the tank. CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. 2. When servicing the fuel lines, loosen the fuel fitting to allow any residual fuel line pressure to be relieved. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Left Side Rocker Arm Assembly: Service and Repair Left Side LEFT SIDE REMOVAL 1. Disconnect battery ground cables (14301). Air Cleaner Assembly 2. Remove air cleaner assembly. 3. Discharge A/C system. 4. Disconnect electrical connectors from A/C system. 5. Disconnect manifold lines from A/C compressor. 6. Remove the four A/C compressor mounting bracket retaining bolts and remove the A/C compressor mounting bracket (2882) (with A/C attached). 7. Remove the interior engine cover. 8. Remove the intake duct tube assembly bolts and the clamps at the air cleaner. Remove the air inlet duct tube assembly. 9. Remove the oil fill tube. 10. Remove the intake duct bracket and retaining nuts. 11. Remove the crankcase breather screws and the breather assembly. 12. Remove the valve cover bolts. 13. Remove the valve cover. WARNING: RED-STRIPED WIRES CARRY 115 VDC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. 14. Disconnect the electrical connectors from the fuel injectors and glow plugs. 15. Remove the valve cover gasket. 16. Remove the two rocker arm bolts (6A527) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2215 Rocker Arm Assembly 17. Remove the rocker arm (6564) assembly. 18. Remove the push rod (6565). NOTE: Be careful when removing the rocker arm snap retaining clip. Do not lose the rocker arm steel ball. 19. Remove the snap retaining clip. 20. Remove the rocker arm and steel ball from the rocker arm pedestal. INSTALLATION 1. Assemble the intake rocker arm or exhaust rocker arm assembly as follows: a. Place the steel ball in the rocker arm cup and lubricate it with clean engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2216 b. Place the rocker arm pedestal on the steel ball. Rocker Arm Cutaway View c. Snap the retaining clip over the rocker arm pedestal groove. 2. Lubricate the push rod ends with engine oil and install the push rod (copper end up). CAUTION: Failure to follow the next step of this procedure could result in bent valves. 3. Rotate the engine until the mark on the crankshaft damper is at 11 O'clock to prevent valve damage when installing the intake rocker arm and exhaust rocker arm. 4. Install the intake rocker arm or exhaust rocker arm. 5. Install the two rocker arm bolts. Tighten rocker arm bolts evenly to 27 Nm (20 ft lb). 6. Install the valve cover gasket. Fuel Injector Connector 7. Connect the electrical connectors to the fuel injectors and glow plugs. 8. Install the valve cover and retaining bolts. Tighten bolts to 11 Nm (8 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2217 9. Connect the engine harness electrical connectors to the valve cover gasket. Install the fuel injector harness clip. 10. Install the wiring harness retainer at the valve cover. 11. Install the tube mounting bracket and retaining nuts. Install the rear nut from inside the vehicle and install the front nut from outside the vehicle. 12. Install the engine oil level indicator tube retaining screw at the tube mounting bracket. 13. Install the alternator and the alternator retaining bolts. Tighten bolts to 40-55 Nm (30-40 ft lb). 14. Install the drive belt. 15. Connect the alternator electrical connectors. 16. Install air cleaner assembly. 17. Connect negative battery cable. 18. Start engine and check for leaks. 19. Install the interior engine cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2218 Rocker Arm Assembly: Service and Repair Right Side Engine Harness View REMOVAL 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect the alternator electrical connectors. 4. Remove the drive belt (8620). 5. Remove the alternator retaining bolts and the alternator (10300). 6. Remove the engine oil level indicator tube retaining screw at the tube mounting bracket. 7. Remove the interior engine cover. 8. Remove the tube mounting bracket retaining nuts and tube mounting bracket at the valve cover (6582). Remove the rear nut from inside the vehicle and remove the front nut from outside the vehicle. 9. Position the engine wiring harnesses aside. 10. Remove the wiring harness retainer at valve cover. WARNING: RED-STRIPED WIRES CARRY 115 VDC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. 11. Remove the fuel injector harness clip, and disconnect the engine harness electrical connectors from the valve cover gasket (6584). 12. Remove the valve cover bolts and valve cover from inside of the vehicle. 13. Disconnect the electrical connectors from the fuel injectors and glow plugs. 14. Remove the valve cover gasket. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2219 Rocker Arm Assembly 15. Remove the two rocker arm bolts (6A527). 16. Remove the rocker arm (6564) assembly. 17. Remove the push rod (6565). NOTE: Be careful when removing the rocker arm snap retaining clip. Do not lose the rocker arm steel ball. 18. Remove the snap retaining clip. 19. Remove the rocker arm and steel ball from the rocker arm pedestal. INSTALLATION 1. Assemble the intake rocker arm or rocker arm assembly as follows: a. Place the steel ball in the rocker arm cup and lubricate it with clean engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2220 b. Place the rocker arm pedestal on the steel ball. Rocker Arm Cutaway View c. Snap the retaining clip over the rocker arm pedestal groove. 2. Lubricate the push rod ends with engine oil and install the push rod (copper end up). CAUTION: Failure to follow the next step of this procedure could result in bent valves. 3. Rotate the engine until the mark on the crankshaft damper is at 11 O'clock to prevent valve damage when installing the intake rocker arm and exhaust rocker arm. 4. Install the intake rocker arm or exhaust rocker arm. 5. Install the two rocker arm bolts. Tighten rocker arm bolts evenly to 27 Nm (20 ft lb). 6. Install the valve cover gasket. Fuel Injector Connector 7. Connect the electrical connectors to the fuel injectors and glow plugs. 8. Install the valve cover and retaining bolts. Tighten bolts to 11 Nm (8 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Left Side > Page 2221 9. Connect the engine harness electrical connectors to the valve cover gasket. Install the fuel injector harness clip. 10. Install the wiring harness retainer at the valve cover. 11. Install the tube mounting bracket and retaining nuts. Install the rear nut from inside the vehicle and install the front nut from outside the vehicle. 12. Install the engine oil level indicator tube retaining screw at the tube mounting bracket. 13. Install the alternator and the alternator retaining bolts. Tighten bolts to 40-55 Nm (30-40 ft lb). 14. Install the drive belt. 15. Connect the alternator electrical connectors. 16. Install air cleaner assembly. 17. Connect negative battery cable. 18. Start engine and check for leaks. 19. Install the interior engine cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side Valve Cover: Service and Repair Right Side RIGHT SIDE Engine Harness View REMOVAL 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect the alternator electrical connectors. 4. Remove the drive belt (8620). 5. Remove the alternator retaining bolts and the alternator (10300). 6. Remove the engine oil level indicator tube retaining screw at the tube mounting bracket. 7. Remove the engine cover. 8. Remove the tube mounting bracket retaining nuts and tube mounting bracket at the valve cover (6582). Remove the rear nut from inside the vehicle and remove the front nut from outside the vehicle. 9. Position the engine wiring harnesses aside. 10. Remove the wiring harness retainer at valve cover. WARNING: RED-STRIPED WIRES CARRY 115 VDC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. 11. Remove the fuel injector harness clip, and disconnect the engine harness electrical connectors from the valve cover gasket (6584). 12. Remove the valve cover bolts and valve cover from inside of the vehicle. 13. Disconnect the electrical connectors from the fuel injectors and glow plugs. 14. Remove the valve cover gasket and cover. INSTALLATION 1. Install the valve cover gasket. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2226 Fuel Injector Connector 2. Connect the electrical connectors to the fuel injectors and glow plugs. 3. Install the valve cover and retaining bolts. Tighten bolts to 11 Nm (8 ft lb). 4. Connect the engine harness electrical connectors to the valve cover gasket. Install the fuel injector harness clip. 5. Install the wiring harness retainer at the valve cover. 6. Install the tube mounting bracket and retaining nuts. Install the rear nut from inside the vehicle and install the front nut from outside the vehicle. 7. Install the engine oil level indicator tube retaining screw at the tube mounting bracket. 8. Install the alternator and the alternator retaining bolts. Tighten bolts to 40-55 Nm (30-40 ft lb). 9. Install the drive belt. 10. Connect the alternator electrical connectors. 11. Install air cleaner assembly. 12. Connect negative battery cable. 13. Start engine and check for leaks. 14. Install the engine cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2227 Valve Cover: Service and Repair Left Side REMOVAL 1. Disconnect battery ground cable (14301). Air Cleaner Assembly 2. Remove air cleaner assembly. 3. Discharge A/C system. 4. Disconnect electrical connectors from A/C system. 5. Disconnect manifold lines from A/C compressor. 6. Remove the four A/C compressor mounting bracket retaining bolts and remove the A/C compressor mounting bracket (2882) (with A/C attached). 7. Remove the interior engine cover. 8. Remove the intake duct tube assembly bolts and the clamps at the air cleaner. Remove the air inlet duct tube assembly. 9. Remove the oil fill tube. 10. Remove the intake duct bracket and retaining nuts. 11. Remove the crankcase breather screws and the breather assembly. 12. Remove the valve cover bolts. 13. Remove the valve cover. 14. Disconnect the electrical connectors from the fuel injectors and glow plugs. 15. Remove the valve cover gasket. INSTALLATION 1. Install the valve cover gasket. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2228 Fuel Injector Connector 2. Connect the electrical connectors to the fuel injectors and glow plugs. 3. Install the valve cover and retaining bolts. Tighten bolts to 11 Nm (8 ft lb). 4. Connect the engine harness electrical connectors to the valve cover gasket. Install the fuel injector harness clip. 5. Install the wiring harness retainer at the valve cover. 6. Install the tube mounting bracket and retaining nuts. Install the rear nut from inside the vehicle and install the front nut from outside the vehicle. 7. Install the engine oil level indicator tube retaining screw at the tube mounting bracket. 8. Install the alternator and the alternator retaining bolts. Tighten bolts to 40-55 Nm (30-40 ft lb). 9. Install the drive belt. 10. Connect the alternator electrical connectors. 11. Install air cleaner assembly. 12. Connect negative battery cable. 13. Start engine and check for leaks. 14. Install the interior engine cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Intake Valve ......................................................................................................................................... ................................................................... 0.0055 in Exhaust Valve ...................................................................................................................................... ................................................................... 0.0055 in Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 2232 Valve Guide: Service and Repair NOTE: If valve guides are damaged, or are larger than 0.3746 in. install repair insert as follows: 1. Drill out valve guide, then ream the drilled bore to correct size for insert sleeve. 2. Chill insert in dry ice, then carefully press insert in place. 3. Finish insert with reamer to specified valve guide diameter. NOTE: Reface valve seat after valve guide has been reamed, then, using a suitable scraping tool, break the sharp corner at top of valve guide. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair REMOVAL 1. Remove the valve cover. 2. Remove the two rocker arm bolts (6A527) and the intake rocker arms (6564) or exhaust rocker arms. 3. Remove the push rod (6565). 4. Disconnect the glow plug electrical connector. 5. Bar the engine over until the piston of the cylinder to be service is at TDC. 6. Install the valve Spring Compressor T94T-6513-AH. NOTE: It may be necessary to strike the valve stem end with a plastic-tipped hammer to loosen the valve spring retainer keys (6518). 7. Remove the valve spring retainer keys. rotator and the valve spring (6513). 8. Remove the valve stem seal (6571). INSTALLATION 1. install the valve stem seal. 2. install the valve spring and rotator. 3. Compress the valve spring and install the valve spring retainer keys using valve spring Compressor T94T-6513-AH. 4. Remove the valve spring Compressor T94T-6513-AH. 5. Lubricate the push rod ends with engine oil and install (copper end up). 6. Rotate the engine until the mark on the crankshaft damper is at 11 O'clock to prevent valve damage when installing the intake rocker arm and exhaust rocker arm. 7. Install the intake rocker arm or exhaust rocker arm. 8. Install the two rocker arm bolts. Tighten rocker arm bolts evenly to 27 Nm (20 ft lb). 9. Install the valve cover gasket. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Intake Valve ......................................................................................................................................... ................................................................... 0.0055 in Exhaust Valve ...................................................................................................................................... ................................................................... 0.0055 in Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 03-21-14 > Oct > 03 > Drive Belts - Belt Shreds and/or Comes Off Drive Belt: Customer Interest Drive Belts - Belt Shreds and/or Comes Off Article No. 03-21-14 10/06/03 FEAD BELT - WEARS, SHREDS, AND/OR COMES OFF - VEHICLES WITH 7.3L DIT ENGINE AND 130 AMP ALTERNATOR BUILT 8/94 THROUGH 5/96 FORD: 1995-1996 E-350, F SUPER DUTY, F-250, F-350 Article 96-17-19 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet, and to update part information and vehicle criteria. ISSUE The Front End Accessory Drive (FEAD) belt may wear, shred and/or come off during deceleration. ACTION Replace the belt tensioner and the FEAD belt. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect the belt for rear edge belt wear and move the tensioner arm to see if it can be cocked out of position. 2. Check for a sticking or binding tensioner by moving the tensioner through its full travel. 3. If any of these conditions exist, replace the belt tensioner following the procedure outlined in the appropriate model/year Service Manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-17-19 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 03-21-14 > Oct > 03 > Drive Belts - Belt Shreds and/or Comes Off Drive Belt: All Technical Service Bulletins Drive Belts - Belt Shreds and/or Comes Off Article No. 03-21-14 10/06/03 FEAD BELT - WEARS, SHREDS, AND/OR COMES OFF - VEHICLES WITH 7.3L DIT ENGINE AND 130 AMP ALTERNATOR BUILT 8/94 THROUGH 5/96 FORD: 1995-1996 E-350, F SUPER DUTY, F-250, F-350 Article 96-17-19 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet, and to update part information and vehicle criteria. ISSUE The Front End Accessory Drive (FEAD) belt may wear, shred and/or come off during deceleration. ACTION Replace the belt tensioner and the FEAD belt. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect the belt for rear edge belt wear and move the tensioner arm to see if it can be cocked out of position. 2. Check for a sticking or binding tensioner by moving the tensioner through its full travel. 3. If any of these conditions exist, replace the belt tensioner following the procedure outlined in the appropriate model/year Service Manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-17-19 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2253 Drive Belt: Specifications NOTE: Tension specified is for both new belts and belts used over five minutes. Minimum Belt Tension ......................................................................................................................... ........................................................ 310 N (70 lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2254 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2255 Drive Belt: Adjustments Belt Tension, Automatically Tensioned Belts Belt Tensioner The automatic belt tensioner will maintain correct belt tension if the correct length belt is on the engine. To verify that the tensioner is working, check to see that the belt length indicator mark on the tensioner is between the maximum and minimum marks. The automatic belt tensioner has no provision for adjustment and will be damaged if forced to travel beyond its operating range. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2256 Drive Belt: Service and Repair Belt Replacement Conditions requiring belt replacement are excessive wear, severe glazing, frayed cords, etc. Replace any belt exhibiting any of these conditions. NOTE: Minor cracks in the ribbed side of the belt are considered acceptable. 1. Install a 15mm closed end wrench on the tensioner pulley bolt and rotate the tensioner arm away from the belt. 2. Remove old belt. Release tensioner slowly. Allowing the tensioner to snap back after the belt is removed may damage the tensioner. Belt Alignment CAUTION:Make sure the belt is properly seated on all pulleys. One revolution of the engine with an incorrectly seated belt may snap tensile members in the belt. 3. Install new belt over pulleys making sure that all belt ribs are correctly seated in the pulley grooves. 4. Rotate the tensioner to position it on the drive belt. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-14 > Nov > 98 > Accessory Drive Belt - Premature Tensioner Wear Drive Belt Tensioner: Customer Interest Accessory Drive Belt - Premature Tensioner Wear Article No. 98-23-14 11/23/98 FEAD - BELT TENSIONER WEAR - VEHICLES WITH 7.3L DI TURBO ENGINE LIGHT TRUCK: 1995-97 F SUPER DUTY 1995-98 ECONOLINE, F-250 HD, F-350 ISSUE Premature wear of the belt tensioner may occur on some vehicles. This may be due to engine torsional input to the Front Engine Accessory Drive (FEAD) system causing excessive tensioner arm movement. ACTION Replace single arm tensioner with new dual arm tensioner. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to the appropriate Service/Workshop Manual for procedure details for the following: 1. Remove drive belt, alternator, belt tensioner, grooved idler pulley, flat idler pulley, and alternator mounting bracket. 2. Modify the alternator mounting bracket as follows: a. Cut off the support boss for the grooved idler pulley. The boss must be cut off flush with the side of the bracket support ribs (Figure 1). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-14 > Nov > 98 > Accessory Drive Belt - Premature Tensioner Wear > Page 2265 b. Cut the boss support rib down 12 mm (0.5") from the boss to support rib of the bracket (Figure 2). c. Modified bracket should appear as in Figure 3. 3. Mount the dual arm tensioner onto the alternator mounting bracket and verify that it lies flat on the mounting surface of the bracket. 4. Reinstall bracket/tensioner assembly, flat idler pulley, and alternator. Install new drive belt The grooved idler is no longer required, discard this part. Remove old belt routing decal and install new belt routing decal. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Powerstroke Diesel Engine Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-14 > Nov > 98 > Accessory Drive Belt - Premature Tensioner Wear > Page 2266 OPERATION DESCRIPTION TIME 982314A Replace Tensioner 1.0 Hr. (F-Series) 982314B Replace Tensioner 1.1 Hr. (Econoline) DEALER CODING CONDITION BASIC PART NO. CODE 6B209 30 OASIS CODES: 497000, 499000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest: > 95135 > Jul > 95 > Drive Belt - Early Wear of Tensioner Pulley Drive Belt Tensioner: Customer Interest Drive Belt - Early Wear of Tensioner Pulley Article No. 95-13-5 07/03/95 ACCESSORY DRIVE BELT - EARLY WEAR OF FEAD TENSIONER PULLEY ON VEHICLES WITH 4.9L ENGINE LIGHT TRUCK: 1987-95 ECONOLINE, F-150-350 SERIES ISSUE: The FEAD tensioner pulley may show signs of early wear and/or erosion on some vehicles. ACTION: If a visual inspection determines an FEAD tensioner pulley has experienced extensive wear or erosion, replace the tensioner pulley assembly with a new steel pulley tensioner assembly (F5TZ-8678-EA). Refer to the appropriate Service Manual and Instruction Sheet # 6829 (included in the kit) for service details. PART NUMBER PART NAME F5TZ-S678-EA Tensioner Pulley Assembly OTHER APPLICABLE ARTICLES: 94-1-10, 94-10-19, 94-5-12 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-95 Model Years, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 951305A Replace Plastic Tensioner 0.3 Hr. With Steel Pulley DEALER CODING CONDITION BASIC PART NO. CODE 6B209 30 OASIS CODES: 402000, 497000, 499000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-14 > Nov > 98 > Accessory Drive Belt - Premature Tensioner Wear Drive Belt Tensioner: All Technical Service Bulletins Accessory Drive Belt - Premature Tensioner Wear Article No. 98-23-14 11/23/98 FEAD - BELT TENSIONER WEAR - VEHICLES WITH 7.3L DI TURBO ENGINE LIGHT TRUCK: 1995-97 F SUPER DUTY 1995-98 ECONOLINE, F-250 HD, F-350 ISSUE Premature wear of the belt tensioner may occur on some vehicles. This may be due to engine torsional input to the Front Engine Accessory Drive (FEAD) system causing excessive tensioner arm movement. ACTION Replace single arm tensioner with new dual arm tensioner. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to the appropriate Service/Workshop Manual for procedure details for the following: 1. Remove drive belt, alternator, belt tensioner, grooved idler pulley, flat idler pulley, and alternator mounting bracket. 2. Modify the alternator mounting bracket as follows: a. Cut off the support boss for the grooved idler pulley. The boss must be cut off flush with the side of the bracket support ribs (Figure 1). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-14 > Nov > 98 > Accessory Drive Belt - Premature Tensioner Wear > Page 2276 b. Cut the boss support rib down 12 mm (0.5") from the boss to support rib of the bracket (Figure 2). c. Modified bracket should appear as in Figure 3. 3. Mount the dual arm tensioner onto the alternator mounting bracket and verify that it lies flat on the mounting surface of the bracket. 4. Reinstall bracket/tensioner assembly, flat idler pulley, and alternator. Install new drive belt The grooved idler is no longer required, discard this part. Remove old belt routing decal and install new belt routing decal. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Powerstroke Diesel Engine Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-14 > Nov > 98 > Accessory Drive Belt - Premature Tensioner Wear > Page 2277 OPERATION DESCRIPTION TIME 982314A Replace Tensioner 1.0 Hr. (F-Series) 982314B Replace Tensioner 1.1 Hr. (Econoline) DEALER CODING CONDITION BASIC PART NO. CODE 6B209 30 OASIS CODES: 497000, 499000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95135 > Jul > 95 > Drive Belt - Early Wear of Tensioner Pulley Drive Belt Tensioner: All Technical Service Bulletins Drive Belt - Early Wear of Tensioner Pulley Article No. 95-13-5 07/03/95 ACCESSORY DRIVE BELT - EARLY WEAR OF FEAD TENSIONER PULLEY ON VEHICLES WITH 4.9L ENGINE LIGHT TRUCK: 1987-95 ECONOLINE, F-150-350 SERIES ISSUE: The FEAD tensioner pulley may show signs of early wear and/or erosion on some vehicles. ACTION: If a visual inspection determines an FEAD tensioner pulley has experienced extensive wear or erosion, replace the tensioner pulley assembly with a new steel pulley tensioner assembly (F5TZ-8678-EA). Refer to the appropriate Service Manual and Instruction Sheet # 6829 (included in the kit) for service details. PART NUMBER PART NAME F5TZ-S678-EA Tensioner Pulley Assembly OTHER APPLICABLE ARTICLES: 94-1-10, 94-10-19, 94-5-12 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-95 Model Years, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 951305A Replace Plastic Tensioner 0.3 Hr. With Steel Pulley DEALER CODING CONDITION BASIC PART NO. CODE 6B209 30 OASIS CODES: 402000, 497000, 499000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt Tensioner: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt Tensioner: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2287 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt Tensioner: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2288 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt Tensioner: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2294 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt Tensioner: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2295 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Technical Service Bulletins > Page 2296 Drive Belt Tensioner: Adjustments The automatic belt tensioner will maintain correct belt tension if the correct length belt is on the engine. There is no provision for adjustment. The tensioner will be damaged if forced to travel beyond its operating range. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2301 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2302 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2303 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2304 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2305 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2306 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2307 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2308 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2309 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2310 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2311 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2312 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2313 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2314 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2315 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2316 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2317 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2318 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2319 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2320 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2321 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2322 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2323 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2324 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2325 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2326 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2327 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2328 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2329 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2330 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2331 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2332 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2333 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2334 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2335 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2336 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2337 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2338 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2339 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2340 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2341 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2342 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2343 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2344 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2345 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2346 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2347 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2348 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2349 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2350 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2351 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2352 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2353 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2354 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2355 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2356 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2357 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2358 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2359 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2360 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2361 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2362 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2363 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2364 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2365 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2366 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2367 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2368 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2369 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2370 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2371 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2372 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2373 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2374 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2375 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2376 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2377 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2378 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2379 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2380 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2381 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2382 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2383 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2384 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2385 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2386 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2387 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2388 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2389 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2390 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2391 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2392 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2393 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2394 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2395 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2396 Engine Mount: Service and Repair REMOVAL AND INSTALLATION 1. Remove engine mount to support assembly attaching bolt and locknut. 2. Remove engine mount to transmission housing attaching bolts and lockwashers. 3. Using suitable floor jack, raise transmission, then remove mount and retainer. 4. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Diagrams Drive Belt Routing Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Motor Oil - Viscosity Grade Recommendation Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Refill (all models) ................................................................................................................................. .......................................................... 12 Qts.(11.4L) Note: Add 2 Qts.(1.9L) when replacing oil filter. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2407 Engine Oil: Fluid Type Specifications Ford Part Name - Motorcraft Motor Oil 15W40 Super Duty SAE-30 Super Duty Ford Part Number - XO-15W40-QSD - XO-30-QSD Ford Supplication - API SG/CE or SG/CD and ESE-M2C153-E Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair Oil Cooler: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect battery ground cables, then drain cooling system. 2. Remove fan shroud, the fan and clutch assembly. NOTE: The clutch fan retaining nut has lefthand threads. 3. Remove the air cleaner assembly. 4. Remove the front oil cooler assembly bolts. 5. Remove the drive belt. 6. Raise and support vehicle. 7. Drain engine oil and remove oil filter. Do not reinstall drain plug. Fig. 18 Exploded View Of Oil Cooler 8. Remove rear oil cooler attaching bolts and the oil cooler, Fig. 18. 9. Reinstall drain plug then reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation PURPOSE To alert the vehicle operator that the engine oil level is low. COMPONENTS The system consists of a float-type sensor mounted to the side of the engine oil pan, an electronic control module, and an instrument panel warning lamp. OPERATION The Check Oil Indicator will light with ignition switch in the START position as a bulb prove-out. When ignition switch is turned to RUN or START position, the control module determines whether sensor is grounded (oil low) or ungrounded (oil not low). If oil level is adequate, light will go out in RUN. If oil level is approximately 1.5 quarts or more low, the relay turns the warning lamp ON. The lamp will remain ON until ignition is turned OFF. After ignition is turned OFF, module will not reset for approximately five minutes. This delay allows time for oil drain back before another reading is allowed to occur. If engine is restarted during this delay period, the last reading will be displayed. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Description and Operation > Page 2414 Oil Level Warning Indicator: Testing and Inspection With oil level at FULL mark on oil dipstick and engine oil warm to assure that oil drains properly from oil sensor, turn ignition ON and start engine. Warning lamp should come on briefly in START for bulb test, then go out. Turn engine OFF. Drain two quarts of oil from engine. Wait approximately five minutes, then restart engine. Warning lamp should come on and stay on. If warning lamp does not come on check fuse, low oil level relay, low oil level sensor and lamp. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Technical Service Bulletins > Customer Interest for Oil Pan: > 03-21-7 > Oct > 03 > Engine - Oil Pan Leak Oil Pan: Customer Interest Engine - Oil Pan Leak Article No. 03-21-7 10/06/03 ENGINE - ENGINE OIL LEAK - 7.3L DIT - MANUAL TRANSMISSION - TRANSMISSION COVER PLATE RUBS ON ENGINE OIL PAN FORD: 1994-1995 F SUPER DUTY, F-250, F-350 Article 95-14-12 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The rear of the engine oil pan, near the crankshaft, may leak oil. This can be caused by the clutch dust cover plate, on the bottom of the manual transmission, coming in contact with the engine oil pan and rubbing a hole through the pan. ACTION Install a new clutch dust cover plate and replace the oil pan. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the Clutch Dust Cover Plate, referring to the appropriate year F-Series Service Manual, Section 08-01. 2. Inspect the rear of the oil pan near the crankshaft, looking for wear marks on the pan. 3. If the wear mark(s) on the oil pan has evidence of oil leaks (crack or hole), replace the Engine Oil Pan Assembly (F4TZ-6675-AAA). Refer to the appropriate year 7.3L Turbo Diesel Service Manual Supplement, Section 03-01D, for service procedures. If the wear mark on the oil pan has no evidence of oil leaking, continue with diagnosis of customer concern over oil leaking. Proceed to Step 4. 4. Install the redesigned Clutch Dust Cover Plate (F5TZ-7007-AD) and visually check to see that the edge of the plate is not rubbing the oil pan. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-14-12 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pan: > 03-21-7 > Oct > 03 > Engine - Oil Pan Leak Oil Pan: All Technical Service Bulletins Engine - Oil Pan Leak Article No. 03-21-7 10/06/03 ENGINE - ENGINE OIL LEAK - 7.3L DIT - MANUAL TRANSMISSION - TRANSMISSION COVER PLATE RUBS ON ENGINE OIL PAN FORD: 1994-1995 F SUPER DUTY, F-250, F-350 Article 95-14-12 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The rear of the engine oil pan, near the crankshaft, may leak oil. This can be caused by the clutch dust cover plate, on the bottom of the manual transmission, coming in contact with the engine oil pan and rubbing a hole through the pan. ACTION Install a new clutch dust cover plate and replace the oil pan. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the Clutch Dust Cover Plate, referring to the appropriate year F-Series Service Manual, Section 08-01. 2. Inspect the rear of the oil pan near the crankshaft, looking for wear marks on the pan. 3. If the wear mark(s) on the oil pan has evidence of oil leaks (crack or hole), replace the Engine Oil Pan Assembly (F4TZ-6675-AAA). Refer to the appropriate year 7.3L Turbo Diesel Service Manual Supplement, Section 03-01D, for service procedures. If the wear mark on the oil pan has no evidence of oil leaking, continue with diagnosis of customer concern over oil leaking. Proceed to Step 4. 4. Install the redesigned Clutch Dust Cover Plate (F5TZ-7007-AD) and visually check to see that the edge of the plate is not rubbing the oil pan. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-14-12 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Technical Service Bulletins > Page 2428 Oil Pan: Service and Repair REMOVAL 1. Remove the engine assembly. Oil Pan Bolts 2. Remove the twelve oil pan retaining bolts. Removing Oil Pan Sealer 3. Remove the oil pan (6675) using Rotunda Quick Blade Release Cold Knife 163-OOO5 or equivalent to cut the RTV sealant on each side rail. 4. Pry up on one side of the oil pan to break the RTV seal at the engine front cover and engine rear cover and remove the oil pan. 5. Remove the oil pump screen cover and tube screws at the engine front cover and remove the nut retaining oil pump screen cover and tube (6622) to the crankshaft main bearing cap stud (6345). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Technical Service Bulletins > Page 2429 Oil Pump Screen Cover 6. Remove the oil pump screen cover and tube. 7. Clean the oil pan mating surfaces and the oil pump screen cover and tube mating surfaces. 8. Inspect the oil pan and the oil pump screen cover and tube for damage. INSTALLATION CAUTION: Do not apply excessive amounts of RTV that could enter Into the oil lubrication system end cause a restriction. 1. Install oil pump inlet tube gasket (8626) on oil pump screen cover and tube mounting flange. Use a small amount of RTV Sealant to hold oil pump inlet tube gasket in place if necessary. 2. Install the oil pump screen cover and tube to the engine front cover and crankshaft main bearing cap stud. 3. Install the oil pump screen cover and tube retaining screws finger-tight. 4. Install the oil pump screen cover and tube retaining nut. 5. Tighten the oil pump screen cover and tube retaining screws to 24 Nm (18 ft lb). CAUTION: Do not apply excessive amounts of RTV that could enter into the oil lubrication system and cause a restriction. NOTE: Install oil pan and retaining bolts within 10 minutes of applying RTV sealant. Oil Pan Bolts 6. Apply a 3.2mm (0.116 inch) bead of Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specification ESE-M4G195-A ESB-M4G92-A to the crankcase oil pan flange on the inside of the oil pan bolt holes. 7. Apply a 6.35mm (0.114 inch) bead of Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specification ESE-M4G195-A or Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Technical Service Bulletins > Page 2430 ESB-4G92-A to the engine front and engine rear cover flange. 8. Install four temporary locating studs in the oil pan bolt holes. 9. Install the oil pan, and eight retaining bolts finger-tight. 10. Remove the four temporary locating studs. 11. Install the remaining four oil pan bolts and tighten. 12. Install the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation Fig. 8 Magnetic Guage The magnetic gauge movement consists of three primary coils, one of which is wound at a 90 degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet which is attached to a shaft and pointer rotates to align to this primary field resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which is attached to the instrument cluster. These gauges require no adjustments, calibrations or maintenance. This gauge system does not use an IVR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests Oil Pressure Gauge: Pinpoint Tests Troubleshooting Chart, Oil Pressure Reads Inaccurate. Troubleshooting Chart, Oil Pressure Reads Inaccurate. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 2436 Oil Pressure Gauge: Component Tests and General Diagnostics TROUBLESHOOTING Tester tool No. 021-00055 or equivalent should be used to diagnose these type of gauges. When troubleshooting, refer to pertaining pinpoint test. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 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 engine is idling, even though oil pressure is adequate. However, light should go out when engine speed is increased. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Technical Service Bulletins > Engine - Poor Idle and/or Low Output Oil Pick Up/Strainer: Technical Service Bulletins Engine - Poor Idle and/or Low Output Article No. 03-21-4 10/06/03 ^ DRIVEABILITY - ROUGH IDLE - DAMAGED OIL PICK-UP OR DAMAGED 0-RING SEAL VEHICLES WITH 7.3L DI TURBO DIESEL ^ ENGINE - LOW OUTPUT - DAMAGED OIL PICK-UP OR DAMAGED/MISSING 0-RING SEAL VEHICLES WITH 7.3L DI TURBO DIESEL FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 95-10-7 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE Some vehicles may exhibit a poor idle quality and/or low output after the engine returns to idle speed. This may be caused by a damaged oil pick-up tube assembly or a missing or damaged 0-ring seal on the oil pick-up tube causing high Injection Control Pressures (ICPs). ACTION If high ICPs are encountered, refer to the following Diagnostic Procedure to determine the cause of the concern. DIAGNOSTIC PROCEDURE 1. Complete all the steps in the 1994-1/2 or 1995 DI Turbo Diesel Diagnostic Guide. Repair any problems which may exist that are not ICP related before proceeding with this procedure. 2. Verify the vehicle has oil with the correct specification and the correct oil level. If the oil quality or service interval is unknown, change the oil and fill with oil of known specification. If the concern still exists, continue with this procedure. WARNING BE SURE THE VEHICLE IS IN "PARK" OR "NEUTRAL" WITH THE PARKING BRAKE APPLIED FOR THE REST OF THIS PROCEDURE. 3. While the engine is idling, note the ICP reading on Rotunda New Generation Star (NGS) Tester (007-00500) or the ICP voltage at the Breakout Box (014-00950104-pin, 014-00322 60-pin). 4. Accelerate the engine to 3300 rpm. If the engine is unable to reach 3300 rpm, this is the result of another failure. Repair this condition before proceeding with this procedure. 5. ICP readings which increase above 1250 psi (1.75 volts) within 15 seconds may be caused by air being drawn into the high pressure oil system. 6. Add an additional 2.8 L (3 qt) of oil to the crankcase (raising the oil level to 16 L (17 qt)). 7. Raise the rear axle of the vehicle so the rear tires are approximately 10" off the ground to fully submerge the pickup tube. 8. Accelerate the engine to 3300 rpm and monitor the ICP readings or ICP voltage. If the ICP readings now stay below 1250 psi (1.75 volts), then there is a failure of the oil pick-up tube assembly. 9. Remove the oil pan per the appropriate Service Manual. 10. Remove the oil pick-up tube and inspect for damaged or missing 0-ring. Inspect the tube assembly for possible damage or cracks. 11. Replace any defective parts as necessary. 12. Fill the crankcase to the proper level (13.2 L (14 qt)), and retest the system to verify the ICP readings are now within specifications. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Technical Service Bulletins > Engine - Poor Idle and/or Low Output > Page 2444 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-10-7 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Oil Pump Pick Up Oil Pick Up/Strainer: Service and Repair Oil Pump Pick Up REMOVAL 1. Remove the engine assembly. Oil Pan Bolts 2. Remove the twelve oil pan retaining bolts. Removing Oil Pan Sealer 3. Remove the oil pan (6675) using Rotunda Quick Blade Release Cold Knife 163-OOO5 or equivalent to cut the RTV sealant on each side rail. 4. Pry up on one side of the oil pan to break the RTV seal at the engine front cover and engine rear cover and remove the oil pan. 5. Remove the oil pump screen cover and tube screws at the engine front cover and remove the nut retaining oil pump screen cover and tube (6622) to the crankshaft main bearing cap stud (6345). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Oil Pump Pick Up > Page 2447 Oil Pump Screen Cover 6. Remove the oil pump screen cover and tube. 7. Clean the oil pan mating surfaces and the oil pump screen cover and tube mating surfaces. 8. Inspect the oil pan and the oil pump screen cover and tube for damage. CAUTION: Do not apply excessive amounts of RTV that could enter Into the oil lubrication system end cause a restriction. INSTALLATION 1. Install oil pump inlet tube gasket (8626) on oil pump screen cover and tube mounting flange. Use a small amount of RTV Sealant to hold oil pump inlet tube gasket in place if necessary. 2. Install the oil pump screen cover and tube to the engine front cover and crankshaft main bearing cap stud. 3. Install the oil pump screen cover and tube retaining screws finger-tight. 4. Install the oil pump screen cover and tube retaining nut. Tighten nut to standard torque specification listed in torque specifications at the end of this section. 5. Tighten the oil pump screen cover and tube retaining screws to 24 Nm (18 ft lb). CAUTION: Do not apply excessive amounts of RTV that could enter into the oil lubrication system and cause a restriction. NOTE: Install oil pan and retaining bolts within 10 minutes of applying RTV sealant. 6. Apply a 3.2mm (116 inch) bead of Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specification ESE-M4G195-A ESB-M4G92-A to the crankcase oil Pan flange on the inside of the oil pan bolt holes. 7. Apply a 6.35mm (114 inch) bead of Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specification ESE-M4G195-A or ESB-4G92-A to the engine front and engine rear cover flange. 8. Install four temporary locating studs in the oil pan bolt holes. 9. Install the oil pan, and eight retaining bolts finger-tight. 10. Remove the four temporary locating studs. 11. Install the remaining four oil pan bolts and tighten. 12. Install the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Oil Pump Pick Up > Page 2448 Oil Pick Up/Strainer: Service and Repair Oil Strainer, Engine REMOVAL 1. Remove the engine assembly. Oil Pan Bolts 2. Remove the twelve oil pan retaining bolts. Removing Oil Pan Sealer 3. Remove the oil pan (6675) using Rotunda Quick Blade Release Cold Knife 163-OOO5 or equivalent to cut the RTV sealant on each side rail. 4. Pry up on one side of the oil pan to break the RTV seal at the engine front cover and engine rear cover and remove the oil pan. 5. Remove the oil pump screen cover and tube screws at the engine front cover and remove the nut retaining oil pump screen cover and tube (6622) to the crankshaft main bearing cap stud (6345). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Oil Pump Pick Up > Page 2449 Oil Pump Screen Cover 6. Remove the oil pump screen cover and tube. 7. Clean the oil pan mating surfaces and the oil pump screen cover and tube mating surfaces. 8. Inspect the oil pan and the oil pump screen cover and tube for damage. CAUTION: Do not apply excessive amounts of RTV that could enter Into the oil lubrication system end cause a restriction. INSTALLATION 1. Install oil pump inlet tube gasket (8626) on oil pump screen cover and tube mounting flange. Use a small amount of RTV Sealant to hold oil pump inlet tube gasket in place if necessary. 2. Install the oil pump screen cover and tube to the engine front cover and crankshaft main bearing cap stud. 3. Install the oil pump screen cover and tube retaining screws finger-tight. 4. Install the oil pump screen cover and tube retaining nut. 5. Tighten the oil pump screen cover and tube retaining screws to 24 Nm (18 ft lb). CAUTION: Do not apply excessive amounts of RTV that could enter into the oil lubrication system and cause a restriction. NOTE: Install oil pan and retaining bolts within 10 minutes of applying RTV sealant. Oil Pan Sealant Application 6. Apply a 3.2mm (1/8 in) bead of Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specification ESE-M4G195-A ESB-M4G92-A to the crankcase oil Pan flange on the inside of the oil pan bolt holes. 7. Apply a 6.35mm (1/4 in) bead of Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specification ESE-M4G195-A or ESB-4G92-A to the engine front and engine rear cover flange. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Oil Pump Pick Up > Page 2450 8. Install four temporary locating studs in the oil pan bolt holes. 9. Install the oil pan, and eight retaining bolts finger-tight. 10. Remove the four temporary locating studs. 11. Install the remaining four oil pan bolts and tighten. 12. Install the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Technical Service Bulletins > Engine - Poor Idle and/or Low Output Oil Pump: Technical Service Bulletins Engine - Poor Idle and/or Low Output Article No. 03-21-4 10/06/03 ^ DRIVEABILITY - ROUGH IDLE - DAMAGED OIL PICK-UP OR DAMAGED 0-RING SEAL VEHICLES WITH 7.3L DI TURBO DIESEL ^ ENGINE - LOW OUTPUT - DAMAGED OIL PICK-UP OR DAMAGED/MISSING 0-RING SEAL VEHICLES WITH 7.3L DI TURBO DIESEL FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 95-10-7 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE Some vehicles may exhibit a poor idle quality and/or low output after the engine returns to idle speed. This may be caused by a damaged oil pick-up tube assembly or a missing or damaged 0-ring seal on the oil pick-up tube causing high Injection Control Pressures (ICPs). ACTION If high ICPs are encountered, refer to the following Diagnostic Procedure to determine the cause of the concern. DIAGNOSTIC PROCEDURE 1. Complete all the steps in the 1994-1/2 or 1995 DI Turbo Diesel Diagnostic Guide. Repair any problems which may exist that are not ICP related before proceeding with this procedure. 2. Verify the vehicle has oil with the correct specification and the correct oil level. If the oil quality or service interval is unknown, change the oil and fill with oil of known specification. If the concern still exists, continue with this procedure. WARNING BE SURE THE VEHICLE IS IN "PARK" OR "NEUTRAL" WITH THE PARKING BRAKE APPLIED FOR THE REST OF THIS PROCEDURE. 3. While the engine is idling, note the ICP reading on Rotunda New Generation Star (NGS) Tester (007-00500) or the ICP voltage at the Breakout Box (014-00950104-pin, 014-00322 60-pin). 4. Accelerate the engine to 3300 rpm. If the engine is unable to reach 3300 rpm, this is the result of another failure. Repair this condition before proceeding with this procedure. 5. ICP readings which increase above 1250 psi (1.75 volts) within 15 seconds may be caused by air being drawn into the high pressure oil system. 6. Add an additional 2.8 L (3 qt) of oil to the crankcase (raising the oil level to 16 L (17 qt)). 7. Raise the rear axle of the vehicle so the rear tires are approximately 10" off the ground to fully submerge the pickup tube. 8. Accelerate the engine to 3300 rpm and monitor the ICP readings or ICP voltage. If the ICP readings now stay below 1250 psi (1.75 volts), then there is a failure of the oil pick-up tube assembly. 9. Remove the oil pan per the appropriate Service Manual. 10. Remove the oil pick-up tube and inspect for damaged or missing 0-ring. Inspect the tube assembly for possible damage or cracks. 11. Replace any defective parts as necessary. 12. Fill the crankcase to the proper level (13.2 L (14 qt)), and retest the system to verify the ICP readings are now within specifications. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Technical Service Bulletins > Engine - Poor Idle and/or Low Output > Page 2455 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-10-7 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Technical Service Bulletins > Page 2456 Oil Pump: Testing and Inspection NOTE: Internal components are not serviceable, if any component is not within specifications, replace pump assembly. 1. Inspect inside of pump housing and inner and outer gears for damage or excessive wear. 2. Inspect pump cover surface for excessive wear. Minor scuff marks are normal. 3. Inspect rotor for nicks, burrs or score marks. Remove minor imperfections with suitable oil stone. Fig. 35 Oil Pump Rotor Tip Inspection 4. Using suitable feeler gauge, inspect inner and outer rotor tip clearance. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Technical Service Bulletins > Page 2457 Fig. 38 Oil pump rotor endplay inspection 5. With rotor installed, place suitable straightedge over rotor assembly and housing, measure rotor endplay between straightedge and inner rotor and outer race, clearance should not exceed 0.005 in 6. Inspect relief valve spring for collapse or wear. 7. Inspect relief valve for free operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Technical Service Bulletins > Page 2458 Oil Pump: Service and Repair REMOVE 1. Remove the radiator. 2. Remove fan shroud and fan clutch. NOTE: The fan clutch has right-hand threads. 3. Raise vehicle. 4. Remove flywheel inspection cover and screws. NOTE: To prevent the crankshaft (6303) from rotating. use a breaker bar for in-vehicle service. 5. Install flywheel holding tool. 6. Remove crankshaft pulley bolt (6A340). Vibration Dampner Removal 7. Remove crankshaft vibration damper (6316) using Damper Remover T79T-6316-A2 (part of T79T-6316-A), Adapter Bolts (part of Damper Remover/Replacer Adapter Set T94T-6379-AH3), and Adapter T79T-6316-A3 (part of TT9T-6316-A). Oil Pump Removal 8. Remove four oil pump housing bolts. 9. Remove oil pump body plate (6616) and square cut O-ring. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Technical Service Bulletins > Page 2459 Oil Pump Assembly 10. Remove inner and outer georotors. 11. Clean oil pump assembly. 12. Inspect inner and outer georotor assembly. Replace the oil pump assembly if any damage is found or if any measurements are not within specification. INSTALLATION Gerotor Installation 1. Install inner georotor on crankshaft. Gerotor O-ring Installation 2. Install oil pump body plate, outer georotor and oring. 3. Install oil pump body plate bolts (4). Tighten bolts to standard torque specification listed at the end of this section. NOTE: A new crankshaft front seal (6700) should be installed whenever the crankshaft vibration damper is removed. NOTE: Apply RTV sealant to the crankshaft keyway prior to crankshaft vibration damper installation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Technical Service Bulletins > Page 2460 Crankshaft Vibration Dampner 4. Install crankshaft vibration damper using Driver/Puller Screw T79T-6316-A1 (part of T79T-316-A), Driver Sleeve T79T-6316-A4 (part of T79T-6316-A), and Thread Adapter (part of T94T-6379-AH3). 5. Install crankshaft pulley bolt and washer. Tighten crankshaft pulley bolt to 287 Nm (212 lb-ft). 6. Remove flywheel holding tool. 7. Install flywheel housing cover and screws. Tighten the screws to 17-23 Nm (13-17 lb-ft). 8. Lower vehicle. 9. Install radiator. 10. Install fan shroud screws and tighten screws to 5-8 Nm (44-71 lb-in). NOTE: The fan clutch has right-hand threads. Install by turning nut clockwise. 11. Install fan and clutch assembly using Fan Clutch Nut Wrench T83T-83 12-B and Fan Clutch Pulley Holder T94T-8312-AH. 12. Check and refill engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation PURPOSE To alert the vehicle operator that the engine oil level is low. COMPONENTS The system consists of a float-type sensor mounted to the side of the engine oil pan, an electronic control module, and an instrument panel warning lamp. OPERATION The Check Oil Indicator will light with ignition switch in the START position as a bulb prove-out. When ignition switch is turned to RUN or START position, the control module determines whether sensor is grounded (oil low) or ungrounded (oil not low). If oil level is adequate, light will go out in RUN. If oil level is approximately 1.5 quarts or more low, the relay turns the warning lamp ON. The lamp will remain ON until ignition is turned OFF. After ignition is turned OFF, module will not reset for approximately five minutes. This delay allows time for oil drain back before another reading is allowed to occur. If engine is restarted during this delay period, the last reading will be displayed. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Description and Operation > Page 2465 Oil Level Warning Indicator: Testing and Inspection With oil level at FULL mark on oil dipstick and engine oil warm to assure that oil drains properly from oil sensor, turn ignition ON and start engine. Warning lamp should come on briefly in START for bulb test, then go out. Turn engine OFF. Drain two quarts of oil from engine. Wait approximately five minutes, then restart engine. Warning lamp should come on and stay on. If warning lamp does not come on check fuse, low oil level relay, low oil level sensor and lamp. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation Fig. 8 Magnetic Guage The magnetic gauge movement consists of three primary coils, one of which is wound at a 90 degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet which is attached to a shaft and pointer rotates to align to this primary field resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which is attached to the instrument cluster. These gauges require no adjustments, calibrations or maintenance. This gauge system does not use an IVR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests Oil Pressure Gauge: Pinpoint Tests Troubleshooting Chart, Oil Pressure Reads Inaccurate. Troubleshooting Chart, Oil Pressure Reads Inaccurate. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 2471 Oil Pressure Gauge: Component Tests and General Diagnostics TROUBLESHOOTING Tester tool No. 021-00055 or equivalent should be used to diagnose these type of gauges. When troubleshooting, refer to pertaining pinpoint test. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 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 engine is idling, even though oil pressure is adequate. However, light should go out when engine speed is increased. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair REMOVAL 1. Remove the transmission. Remove the Flex Plate. 2 Remove the five crankshaft rear oil seal retaining bolts and the crankshaft rear oil seal (6701). 3 Clean the crankshaft rear oil seal sealing surfaces. 4 Inspect the crankshaft rear oil seal and wear sleeve for damage. replace as necessary. Wear Ring Remover 5 Using Crankshaft Rear Wear Ring Remover T94T-6701-AH1, Forcing Screw T84T-7025-B. Remover Tube T77J-7025-B and Crankshaft Rear Wear Ring Remover Sleeve T94T-6701-AH21 remove the crankshaft rear wear ring. INSTALLATION 1 Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specification ESE-M4G195-A or ESE-M4G92-A to the rear oil seal retaining ring and five crankshaft rear oil seal retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2479 Crankshaft Seal Remover 2 Using Crankshaft Seal Replacer T94T-6701-AH3. Crankshaft Seal Replacer T94T-AH4. Driver Sleeve T79T-6316-A4 (part of T79T-6316-A), and Guide Pins T94P-7000-P, install crankshaft wear ring and crankshaft rear oil seal. 3 Install the five crankshaft rear oil seal retaining bolts. 4 Remove installation tools. 5 Install the Flex Plate. Install transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair REMOVAL 1. Remove the valve cover. 2. Remove the two rocker arm bolts (6A527) and the intake rocker arms (6564) or exhaust rocker arms. 3. Remove the push rod (6565). 4. Disconnect the glow plug electrical connector. 5. Bar the engine over until the piston of the cylinder to be service is at TDC. Valve Spring Tool 6. Install the valve Spring Compressor T94T-6513-AH. NOTE: It may be necessary to strike the valve stem end with a plastic-tipped hammer to loosen the valve spring retainer keys (6518). 7. Remove the valve spring retainer keys. rotator and the valve spring (6513). 8. Remove the valve stem seal (6571). INSTALLATION 1. install the valve stem seal. 2. install the valve spring and rotator. 3. Compress the valve spring and install the valve spring retainer keys using valve spring Compressor T94T-6513-AH. 4. Remove the valve spring Compressor T94T-6513-AH. 5. Lubricate the push rod ends with engine oil and install (copper end up). CAUTION: Failure to follow the next step of this procedure could result in bent valves. 6. Rotate the engine until the mark on the crankshaft damper is at 11 O'clock to prevent valve damage when installing the intake rocker arm and exhaust rocker arm. 7. Install the intake rocker arm or exhaust rocker arm. 8. Install the two rocker arm bolts. Tighten rocker arm bolts evenly to 27 Nm (20 ft lb). 9. Install the valve cover gasket. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair Crankshaft Gear/Sprocket: Service and Repair CAUTION: The crankshaft sprocket (6306) is not serviced separately from the crankshaft (6303). Do not attempt to remove the crankshaft sprocket or damage to the crankshaft and crankshaft sprocket will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair Timing Cover: Service and Repair Engine Front Cover Bolt Locations REMOVAL 1. Remove the engine. 2. Remove the water pump. 3. Remove the crankshaft vibration damper (6316). 4. Remove the oil pan (6675) and oil pump screen cover and tube (6622). 5. Remove the four engine front cover bolts. 6. Remove the engine front cover and the two engine front cover gaskets (6020). 7. Clean the engine front cover, oil pan and cylinder block mating surfaces. INSTALLATION Engine Front Cover 1. Install the two new engine front cover gaskets and apply Silicone Rubber D6AZ- 19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to the sealing grooves in the engine front cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 2490 2. Install the engine front cover and the four retaining bolts finger-tight. 3. Install the water pump. 4. Tighten the four engine front cover bolts to 20 Nm (15 ft lb). 5. Install the oil pan and oil pump screen cover and tube. 6. Install the crankshaft vibration damper. 7. Install the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Fuel Pressure Regulator The fuel pressure test port is a Schrader valve mounted on the fuel pressure regulator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments Idle Speed: Adjustments Engine idle speed and injection timing are controlled by the Powertrain Control Module (PCM) and are not adjustable. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Tag, disconnect, and position out of the way, any tubes or hoses attached to the air cleaner outlet tube. 2. Loosen clamps as necessary, at both ends of the air cleaner outlet tube. 3. Disconnect and remove air cleaner outlet tube. INSTALLATION Follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation Air Filter Element: Description and Operation AIR INDUCTION SYSTEM Air enters a dry-type engine air cleaner and travels through a pleated, chemically treated, water resistant paper air cleaner element to remove contaminants before entering the engine induction system. The 7.3L Direct Injection (DI) turbo diesel engine also uses a pleated-paper upright type element. Use of other than specific Ford replacement filters may result in significantly shortened filter life and consequent dirt injection. AIR CLEANER ELEMENT Dry-type engine air cleaners are standard on all light truck vehicles. The 7.3L diesel engine also uses a pleated-paper panel type air cleaner element which features an expanding foam filter media attached to the sides of the paper. Use of other than specific Ford replacement air cleaner elements may result in significantly shortened filter life and consequent engine damage. The air cleaner elements should be inspected, and/or replaced periodically according to the maintenance schedule. The air cleaner system has an Intake Air Temperature (IAT) mounted in the outlet hose to monitor engine inlet air temperature. Air Restriction Gauge On diesel engines, replace air cleaner element according to air restriction gauge. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 2506 Air Filter Element: Testing and Inspection Air Restriction Gauge Air Restriction Gauge The 7.3L diesel engine air induction system uses an air restriction indicator to indicate when to change the air cleaner element. The air cleaner element should be replaced when the yellow band in the indicator reaches the CHANGE FILTER mark. Engine performance and fuel economy are adversely affected when maximum restriction is reached. After servicing the air cleaner element, the air restriction indicator can be reset by pushing the button on the end of the indicator. The air restriction indicator is located on the clean-air side of the engine air cleaner. Air Inlet Restriction Check The best method for determining dry-type air cleaner maintenance periods on diesel equipped vehicles is by periodically checking the air restriction indicator. It is recommended that the air restriction indicator be used to determine service intervals. A visual inspection of the air cleaner element will not determine the need for service. Overservicing is not recommended. Air Cleaner Element CAUTION: If the air cleaner element, engine air cleaner or air cleaner outlet tube is removed, use a clean shop rag to prevent contaminants from entering the engine. 1. Replace the air cleaner element according to the maintenance schedule. 2. Check the old air cleaner element. It could help to detect foreign material on the sealing surface that is causing leakage. A streak of dust on the clean air side of the air cleaner element seal is the tell-tale sign. If it exists, be sure the cause is removed before installing a new air cleaner element. 3. Inspect the new air cleaner element for damage. Always look for possible shipping or handling damage. Pay particular attention to the seals. Check for cuts, etc.. Do not use a damaged air cleaner element. 4. Insert the new air cleaner element properly. Cover pressure is not necessary to compress the air cleaner element seal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 2507 Air Filter Element: Service and Repair REMOVAL CAUTION: A special filtering medium is required on Diesel engines. Use only a specific Ford replacement. Use of other Air Cleaner Elements (ACL Element) could result in serious engine damage. Do not attempt to clean ACL Element. Discard and replace. 1. Disconnect and position out of the way any tubes, hoses, or ducts that will interfere with opening the engine Air Cleaner (ACL). CAUTION: Whenever the ACL system is taken apart, use a clean shop rag to prevent contaminants from entering the air intake system. 2. Remove clamps or screws as necessary to remove ACL cover. 3. Remove the ACL cover. 4. Remove the ACL Element, being careful to not loosen any dirt or debris. INSTALLATION 1. Before installing a new ACL Element, check the following items: - Gasket surfaces should be clean and undamaged. - Inlet tube should be clean and undamaged. - ACL Element should be dry and free of holes, ruptures, dents, and damaged gaskets. - Inspect inlet snouts for possible obstructions. 2. Install new ACL Element. 3. Replace upper ACL housing. 4. Attach any tubes, hoses, or ducts as required to upper ACL housing. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information Fuel Pressure Release: Customer Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information > Page 2513 Fuel Pressure Release: Technician Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2514 Fuel Pressure Release: Service and Repair 1. Remove fuel tank filler cap to relieve any pressure in the tank. CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. 2. When servicing the fuel lines, loosen the fuel fitting to allow any residual fuel line pressure to be relieved. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order: 1-2-7-3-4-5-6-8 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression pressures are considered within specification if they are at least 350 psi and the lowest reading cylinder is within 50 psi of the highest. NOTE: Variations exceeding specifications indicate an improperly seated valve or worn/broken piston rings. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2521 Compression Check: Testing and Inspection 1. Warm engine to normal operating temperature, then turn ignition off. 2. Remove the alternator retaining bolt and electrical connectors and and position aside. 3. Remove drive belt. 4. Remove the alternator bracket retaining bolts. 5. Remove the alternator with the bracket attached. 6. Remove the dipstick assembly and bracket. 7. Remove the fuel injector wiring harness connector from the valve cover gasket. 8. Remove valve covers. 9. Unplug harness from the glow plugs and remove all glow plugs. 10. Install suitable compression gauge into cylinder No. 1 glow plug hole. 11. Crank engine at least five compression strokes with ignition switch off. Record highest reading indicated. 12. Repeat compression check on each cylinder. 13. Compression pressures are considered within specification if they are at least 350 psi and the lowest reading cylinder is within 50 psi of the highest. 14. Variations exceeding specifications indicate an improperly seated valve or worn/broken piston rings. 15. Reverse procedure to reassemble after tests. CAUTION: Do not add oil to cylinder as this may cause hydrostatic lock. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations Valve Clearance: Locations Front To Rear Left ....................................................................................................................................................... ........................................................ I-E-I-E-I-E-I-E Right .................................................................................................................................................... ......................................................... E-I-E-I-E-I-E-I Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations > Page 2525 Valve Clearance: Adjustments These engines use hydraulic lifters and there is no provision for adjustment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair REMOVAL 1. Partially drain the engine cooling system. 2. Remove the air cleaner housing assembly. 3. Remove the upper radiator hose clamps and upper radiator hose (8260). 4. Disconnect the radiator coolant recovery reservoir hose at radiator (8005). 5. Remove the fan and clutch assembly using Fan Clutch Nut Wrench T83T-6312-B and Fan Clutch Pulley Holder T94T-6312-AH. Set fan and clutch assembly in fan shroud (8146). NOTE: the fan clutch assembly has right-hand thread. Install by turning nut clockwise. 6. Remove the fan shroud screws. 7. Remove the fan shroud, and fan and clutch assembly. 8. Loosen the water pump pulley bolts. 9. Remove the drive belt (8620). 10. Remove the water pump pulley bolts and water pump pulley (8509). 11. Disconnect the engine coolant temperature sensor (ECT sensor) (12A648). 12. Disconnect the heater hose and clamp from water pump. 13. Disconnect the engine coolant temperature sensor electrical connector. 14. Remove the water pump inlet bolts and water pump inlet. 15. Remove water pump bolts. 16. Remove water pump and water pump housing gasket (8507). 17. Clean gasket surfaces. Water Pump INSTALLATION 1. Install the water pump and water pump housing gasket. 2. Install the water pump bolts, tighten bolts to 20 Nm (15 ft lb). 3. Install the water pump inlet and bolts, tighten bolts to 20 Nm (15 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Page 2529 4. Connect the engine coolant temperature sensor electrical connector. 5. Install the heater hose and clamp to the water pump. 6. Connect the engine coolant temperature sensor. 7. Install the water pump pulley and start the water pump pulley bolts. 8. Install the drive belt. 9. Tighten the water pump pulley bolts to 16-24 Nm (12-18 ft. lb.). 10. Install the fan shroud, and fan and clutch assembly. 11. Install the fan shroud screws. 12. Install the fan and clutch assembly using Fan Clutch Nut Wrench T83T-6312-B and Fan Clutch Pulley Holder T94T-6312-AH. NOTE: The fan clutch assembly has right-hand thread. Install by turning nut clockwise. 13. Install the radiator coolant recovery reservoir hose to radiator. 14. Install the upper radiator hose and clamps. 15. Install the air cleaner housing assembly. 16. Refill and bleed the engine cooling system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2535 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2536 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2537 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2538 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 24 qts .............................................................................................................................................................. .......................................... Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2541 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection Fan Blade: Testing and 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 ensured 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 the clearance between the fan blade touching surface and the opposite blade is more than 0.090 in (2 mm), replace the fan. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection > Page 2549 Fan Blade: Service and Repair NOTE: The clutch assembly nut has a righthand thread and must be rotated counterclockwise to remove it. 1. Partially drain cooling system, then remove upper radiator hose and disconnect coolant reservoir hose at radiator. 2. Remove fan clutch from water pump pulley by turning clutch assembly nut. Use fan clutch holding tool No. T84T-6312-C, or equivalent, and fan clutch nut wrench tool No. T93T-6312-B, or equivalent. 3. Remove fan shroud retaining screws. 4. Remove fan blade, fan clutch and shroud. 5. If fan blade and clutch must be separated, remove remaining bolts attaching fan blade to fan clutch. 6. Reverse procedure to install. Torque fan blade to fan clutch attaching bolts to 12-18 ft lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Customer Interest for Fan Clutch: > 951616 > Aug > 95 > A/C Lack of Cooling at Idle Fan Clutch: Customer Interest A/C - Lack of Cooling at Idle Article No. 95-16-16 08/14/95 AIR CONDITIONING - LACK OF COOLING AT IDLE - A/C SYSTEM SHUTS OFF DUE TO HIGH SYSTEM PRESSURES - 7.3L DI TURBO F-SERIES BUILT BEFORE 4/14/95 AND 7.3L DI TURBO ECONOLINES BUILT BEFORE 4/21/95 LIGHT TRUCK: 1994-95 F SUPER DUTY, F-250, F-350 1995 E-25O, E-350 ISSUE: The A/C system may shut off due to high system pressures and/or there may be a lack of cooling at an idle. This may be caused by insufficient air flow being provided by the fan clutch. The fan clutch has too low of an idle rpm. ACTION: Verify the fan clutch is the cause of the concern and, if necessary, replace the fan clutch. The new fan clutch will have a higher idle rpm. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Apply reflective tape to one (1) fan blade. 2. Run engine at 3000 RPMs until fan clutch disengages, which should occur within 60 seconds. 3. Let engine return to an idle for 2 minutes. 4. Measure the fan speed at 2 minutes and again at 10 minutes using a Newark Electronics 6611 Series (or equivalent) tachometer by pointing the probe at the fan blades a distance of 6-12" (15.2-30.5 cm) from the fan blades. 5. If the fan speed is below 500 RPMs, replace the fan clutch with a new fan clutch (F5TZ-8A616-KB). If the fan speed is above 500 RPMs, refer to the appropriate Service Manual for proper diagnostic procedures. PART NUMBER PART NAME F5TZ-8A616-KB Fan Clutch OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 951616A Inspect And Replace Fan 0.9 Hr. Clutch DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 OASIS CODES: 208000, 208200, 208999, 402000, 499000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Clutch: > 951616 > Aug > 95 > A/C - Lack of Cooling at Idle Fan Clutch: All Technical Service Bulletins A/C - Lack of Cooling at Idle Article No. 95-16-16 08/14/95 AIR CONDITIONING - LACK OF COOLING AT IDLE - A/C SYSTEM SHUTS OFF DUE TO HIGH SYSTEM PRESSURES - 7.3L DI TURBO F-SERIES BUILT BEFORE 4/14/95 AND 7.3L DI TURBO ECONOLINES BUILT BEFORE 4/21/95 LIGHT TRUCK: 1994-95 F SUPER DUTY, F-250, F-350 1995 E-25O, E-350 ISSUE: The A/C system may shut off due to high system pressures and/or there may be a lack of cooling at an idle. This may be caused by insufficient air flow being provided by the fan clutch. The fan clutch has too low of an idle rpm. ACTION: Verify the fan clutch is the cause of the concern and, if necessary, replace the fan clutch. The new fan clutch will have a higher idle rpm. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Apply reflective tape to one (1) fan blade. 2. Run engine at 3000 RPMs until fan clutch disengages, which should occur within 60 seconds. 3. Let engine return to an idle for 2 minutes. 4. Measure the fan speed at 2 minutes and again at 10 minutes using a Newark Electronics 6611 Series (or equivalent) tachometer by pointing the probe at the fan blades a distance of 6-12" (15.2-30.5 cm) from the fan blades. 5. If the fan speed is below 500 RPMs, replace the fan clutch with a new fan clutch (F5TZ-8A616-KB). If the fan speed is above 500 RPMs, refer to the appropriate Service Manual for proper diagnostic procedures. PART NUMBER PART NAME F5TZ-8A616-KB Fan Clutch OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 951616A Inspect And Replace Fan 0.9 Hr. Clutch DEALER CODING CONDITION BASIC PART NO. CODE 8A616 42 OASIS CODES: 208000, 208200, 208999, 402000, 499000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Technical Service Bulletins > Page 2563 Fan Clutch: Description and Operation Variable Speed Fan With Coiled Bi-Metallic Thermostatic Spring PURPOSE The fan clutch causes fan speed to increase with a rise in temperature and to decrease as temperature decreases. OPERATION The fan drive clutch is a fluid coupling containing silicone oil. Fan speed is regulated by the torque-carrying capacity of the silicone oil. The more silicone oil in the coupling, the greater the fan speed, and the less silicone oil, the slower the fan speed. The fan drive clutch used is the coiled bi-metallic thermostatic spring type. The fan drive clutch uses a heat-sensitive, coiled bi-metallic spring connected to an opening plate, to control fan speed based on cooling need. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 the clutch. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 2566 Fan Clutch: Testing and Inspection Fan Clutch Noise Fan clutch noise can sometimes be noticed when the clutch is engaged for maximum cooling. Clutch noise is also noticeable within the first few minutes after starting the engine while the clutch is redistributing the silicone fluid 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 the fan. If the fan cannot be rotated manually or there is a rough, abrasive feel as it is rotated, the clutch should be replaced. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 2567 Fan Clutch: Testing and Inspection Fan Clutch Operational Test WARNING: Do not operate the engine until the fan has been first checked for possible cracks and separations. 1. Run engine at a fast idle speed 1500 RPM until normal operating temperature is reached. This can be done more quickly by blocking off the front of the radiator with cardboard. NOTE: Regardless of temperatures, the unit must be operated for at least five minutes immediately before being tested. 2. 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 the coupling is operating satisfactorily. - If very little effort is required to turn the fan, the coupling is not operating properly and should be replaced. Bi-Metallic Coiled Spring Removal 3. The clutch fan may be tested while the vehicle is being driven. To check, disconnect the bi-metallic spring, and rotate it 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 2568 Fan Clutch: Testing and Inspection Fan Looseness Lateral movement can be observed at the fan blade tip under various temperature conditions because of the type of bearing used. This movement should not exceed 1/4 in (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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 2569 Fan Clutch: Service and Repair NOTE: The clutch assembly nut has a righthand thread and must be rotated counterclockwise to remove it. 1. Partially drain cooling system, then remove upper radiator hose and disconnect coolant reservoir hose at radiator. 2. Remove fan clutch from water pump pulley by turning clutch assembly nut. Use fan clutch holding tool No. T84T-6312-C, or equivalent, and fan clutch nut wrench tool No. T93T-6312-B, or equivalent. 3. Remove fan shroud retaining screws. 4. Remove fan blade, fan clutch and shroud. 5. If fan blade and clutch must be separated, remove remaining bolts attaching fan blade to fan clutch. 6. Reverse procedure to install. Torque fan blade to fan clutch attaching bolts to 12-18 ft lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 2570 Fan Clutch: Tools and Equipment Fan Clutch Holding Tool AST tool# 8005 Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan. 2009 Suggested user price: $41.20 Assenmacher Specialty Tools 1 800 525 2943 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation Engine Oil Temperature (EOT) Sensor: Description and Operation Engine Oil Temperature Sensor The Engine Oil Temperature (EOT) sensor changes resistance in response to changing temperature of the engine oil. The engine oil temperature sensor resistance decreases as the engine oil temperature increases providing a signal to the Powertrain Control Module (PCM), indicating the temperature of the engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation > Page 2578 Engine Oil Temperature (EOT) Sensor: Service and Repair REMOVAL 1. Disconnect engine oil temperature sensor electrical connector. 2. Approximately 0.94 liters (one quart) of engine oil must be removed prior to sensor removal. Remove one quart of engine oil from high pressure oil pump reservoir using Rotunda Vacuum Tester 014-R1058 or equivalent. 3. Remove engine oil temperature sensor. INSTALLATION 1. Install engine oil temperature sensor. 2. Connect engine oil temperature sensor electrical connector. 3. Fill engine oil to proper level. 4. Refill oil pump reservoir with engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic Engine Coolant Temperature Sender: Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic > Page 2583 6. In the Remarks Section, write "Returned per TSB 95-13-2". 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 FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - On Car Pressure Test For Warranty Claim Heater Core: Technical Service Bulletins Heater Core - On Car Pressure Test For Warranty Claim Article No. 97-19-11 09/15/97 COOLING SYSTEM - "ON-VEHICLE" HEATER CORE PRESSURE TEST REQUIRED FOR WARRANTY CLAIM FORD: 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-98 ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: An "On-Vehicle" heater core pressure test is required before replacing any heater core within the warranty period. ACTION: Perform the "On-Vehicle" heater core pressure test by referring to the following heater core leak test procedure. HEATER CORE LEAK TEST PROCEDURE Use the heater core pressure test to determine if the heater core is leaking. Symptoms associated with a leaking heater core include: ^ Engine coolant leaking into the passenger compartment ^ Engine coolant blown onto the windshield during defrost operation ^ Engine coolant odor inside the passenger compartment 1. Partially drain cooling system. 2. Disconnect both heater core hoses. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - On Car Pressure Test For Warranty Claim > Page 2588 3. Attach two (2) pieces of heater hose to the heater core inlet and outlet tubes and clamp (Figure 1). 4. Install Plug (part of 014-R1072) into one (1) heater hose and clamp (Figure 1). 5. Fill heater core and hoses with water. 6. Install Adapter (part of 0144-R1072) into other heater hose and clamp (Figure 1). 7. Attach Radiator/Heater Core Pressure Tester (014-R1072) to Adapter (part of 014-R1072) (Figure 1). 8. Close the bleed valve and the tester and pump air into the heater core until 241 kPa (35 psi) is reached on the tester gauge. 9. Observe the gauge after 3 minutes. The pressure should not drop. If the pressure does drop, there is a leak. Check the hose connections and retest if you find a leak. 10. Replace heater core if pressure drops and hose connections do not leak. 11. Do not replace heater core if pressure does not drop. Pressure test engine cooling system for leaks elsewhere. 12. Reconnect heater core and refill cooling system after all necessary repairs. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208999, 290000, 402000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Auxiliary (Rear) Heater Core: Service and Repair Auxiliary (Rear) Heater Core (Rear) REMOVE 1. Remove the third, fourth and fifth bench seats (if equipped). 2. Remove the left center bolster trim panel, left lower front trim panel, left rear lower and upper trim panels (if equipped). 3. Remove the six mounting screws and remove the heater core cover (18B300). 4. Clamp off the heater water hoses (18472) that connect to the heater core (18476) to prevent coolant from spilling when the heater core is removed. 5. Loosen the clamps that secure the heater water hoses to the heater core and disconnect the heater core from the heater water hoses. 6. Remove the heater core. 7. Remove the heater core case seal (18658) from the heater core. INSTALL 1. Install the heater core case seal onto the heater core. 2. Connect the heater core to the heater water hoses, making sure to install the inlet and outlet heater water hoses in their proper positions. 3. Tighten the inlet and outlet clamps. 4. Unclamp the heater core. 5. Place the heater core and seal into the auxiliary heater and air conditioner assembly. 6. Install the heater core cover and six mounting screws. 7. Fill the cooling system to specification and check for leaks. 8. Install the left lower and upper trim panels, left lower front trim panel and the left center bolster trim panel (if equipped). 9. Install the third, fourth and fifth bench seats (if equipped). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Auxiliary (Rear) > Page 2591 Heater Core: Service and Repair Main (Front) REMOVAL AND INSTALLATION 1. Drain cooling system. 2. Remove the heater water hoses from the heater core in the engine compartment using Quick Disconnect tool T85T-18539-AH, and plug hoses. 3. Remove modesty panel which runs along the lower edge of the instrument panel (04320). Fig. 7 Heater Core Replacement 4. Remove the six screws from the heater core cover (18B300) Fig. 7. located on both sides of the heater assembly case. 5. Remove heater core cover. 6. Remove heater core and heater core case seal (18658) from the heater assembly. 7. Reverse procedure to install, refill cooling system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hose Clamp, Cooling System > Component Information > Technical Service Bulletins > Customer Interest for Hose Clamp: > 95616 > Mar > 95 > Cooling System Leaking Radiator Hose Joint Hose Clamp: Customer Interest Cooling System - Leaking Radiator Hose Joint Article No. 95-6-16 03/27/95 ^ COOLING SYSTEM - LEAKING RADIATOR HOSE JOINT - 4.9L/5.0L/5.8L/7.3L DIT/7.5L UPGRADED HOSE CLAMPS ^ LEAKS - COOLANT - 4.9L/5.0L/5.8L/7.3L DIT/7.5L - RADIATOR HOSE JOINT - UPGRADED HOSE CLAMPS LIGHT TRUCK: 1995-96 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: A coolant leak may occur at the radiator hose joints. This can be caused by: ^ Debris on the sealing surface ^ Misassembly of the hose and/or clamp ^ Defective or damaged hose clamp ACTION: Refer to the following procedures for diagnosis and repair. "Mega" hose clamps are to be used, if needed, because they have 30% more clamping force than clamps used in the past. They expand and contract with the thermal cycling of the joint, thus retaining their clamp load and efficiently sealing the joint over long periods of time. The screw-type dual-wire and worm gear style band clamps are less robust under climatic and system thermal cycling. NOTE: THE "MEGA" CLAMPS WERE SPECIFICALLY SIZED FOR 1995 AND LATER VEHICLES. THEY ARE NOT APPROPRIATE FOR VEHICLES BEFORE THE 1995 MODEL YEAR BECAUSE THE JOINT SEAL CONFIGURATION AND DIMENSIONS ARE DIFFERENT. NOTE: IF A 1995 VEHICLE IS RECEIVED WITH A DUAL-WIRE CLAMP, REPLACE IT WITH A COMPARABLE BAND CLAMP. SERVICE PROCEDURE 1. Pressure test the system to determine the location of the leak. Proceed with the following steps only if it is a radiator hose joint that is leaking. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hose Clamp, Cooling System > Component Information > Technical Service Bulletins > Customer Interest for Hose Clamp: > 95616 > Mar > 95 > Cooling System Leaking Radiator Hose Joint > Page 2600 2. Reseat the clamp by using a pair of pliers or vise grips to squeeze the clamp tangs together (loosen the clamp), reseat the hose, then re-release the clamp. Pay close attention that the clamp is straight (perpendicular to the hose) and is not cocked over the bead (Figure 1). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hose Clamp, Cooling System > Component Information > Technical Service Bulletins > Customer Interest for Hose Clamp: > 95616 > Mar > 95 > Cooling System Leaking Radiator Hose Joint > Page 2601 3. Pressure test the system again. If the leak persists, check the radiator hose clamp for damage. If damage is observed, replace the damaged part per the following installation steps. The clamps to be used are as shown. 4. If only the clamp is to be removed, residual glue (located 180° away from the tangs) may exist on the hose. The glue will generally dissipate over time with the thermal cycling of the engine. If necessary, remove the glued clamp by applying a heat gun at 420°F (21500) to the glued portion for approximately 1 minute. If any foreign material remains on (or if any material is removed from) the hose, a sealing discontinuity will result and the hose must be replaced. Proper installation of the hose and clamp is essential for the joint to be effective. The following steps should be taken to ensure a robust hose joint. ENSURING A ROBUST HOSE JOINT 1. Push the hose onto the connector until it is completely seated against the hose stop. 2. Release the "Mega" clamp by carefully removing the retaining clip using pliers or vise grips. During removal, the clip should be held securely at all times. Do not pry or pop the clip off the clamp. Application Chart 3. Check that the clamp is straight, fully released and seated on the sealing area of the hose and connector. The clamp should not be partially or completely cocked over or on top of the bead at the end of the connector. The connector, radiator hose and clamp are shown in Figure 1. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hose Clamp, Cooling System > Component Information > Technical Service Bulletins > Customer Interest for Hose Clamp: > 95616 > Mar > 95 > Cooling System Leaking Radiator Hose Joint > Page 2602 Parts Block NOTE: THE "MEGA" CLAMPS WERE SPECIFICALLY SIZED FOR 1995 AND LATER VEHICLES. THEY ARE NOT APPROPRIATE FOR VEHICLES BEFORE THE 1995 MODEL YEAR BECAUSE THE JOINT SEAL CONFIGURATION AND DIMENSIONS ARE DIFFERENT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950616A Pressure Test Cooling 0.3 Hr. System. Reseat Clamps As Required 950616B Additional Time To Replace 0.3 Hr. One (1) Clamp 950616C Additional Time To Replace 0.4 Hr. Two (2) Or More Clamps 950616D Additional Time To Replace 0.4 Hr. Upper Or Lower Radiator Hose 950616E Additional Time To Replace 0.5 Hr. Both Radiator Hoses DEALER CODING BASIC PART NO. CONDITION CODE 8287 33 OASIS CODES: 402000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hose Clamp, Cooling System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose Clamp: > 95616 > Mar > 95 > Cooling System - Leaking Radiator Hose Joint Hose Clamp: All Technical Service Bulletins Cooling System - Leaking Radiator Hose Joint Article No. 95-6-16 03/27/95 ^ COOLING SYSTEM - LEAKING RADIATOR HOSE JOINT - 4.9L/5.0L/5.8L/7.3L DIT/7.5L UPGRADED HOSE CLAMPS ^ LEAKS - COOLANT - 4.9L/5.0L/5.8L/7.3L DIT/7.5L - RADIATOR HOSE JOINT - UPGRADED HOSE CLAMPS LIGHT TRUCK: 1995-96 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: A coolant leak may occur at the radiator hose joints. This can be caused by: ^ Debris on the sealing surface ^ Misassembly of the hose and/or clamp ^ Defective or damaged hose clamp ACTION: Refer to the following procedures for diagnosis and repair. "Mega" hose clamps are to be used, if needed, because they have 30% more clamping force than clamps used in the past. They expand and contract with the thermal cycling of the joint, thus retaining their clamp load and efficiently sealing the joint over long periods of time. The screw-type dual-wire and worm gear style band clamps are less robust under climatic and system thermal cycling. NOTE: THE "MEGA" CLAMPS WERE SPECIFICALLY SIZED FOR 1995 AND LATER VEHICLES. THEY ARE NOT APPROPRIATE FOR VEHICLES BEFORE THE 1995 MODEL YEAR BECAUSE THE JOINT SEAL CONFIGURATION AND DIMENSIONS ARE DIFFERENT. NOTE: IF A 1995 VEHICLE IS RECEIVED WITH A DUAL-WIRE CLAMP, REPLACE IT WITH A COMPARABLE BAND CLAMP. SERVICE PROCEDURE 1. Pressure test the system to determine the location of the leak. Proceed with the following steps only if it is a radiator hose joint that is leaking. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hose Clamp, Cooling System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose Clamp: > 95616 > Mar > 95 > Cooling System - Leaking Radiator Hose Joint > Page 2608 2. Reseat the clamp by using a pair of pliers or vise grips to squeeze the clamp tangs together (loosen the clamp), reseat the hose, then re-release the clamp. Pay close attention that the clamp is straight (perpendicular to the hose) and is not cocked over the bead (Figure 1). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hose Clamp, Cooling System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose Clamp: > 95616 > Mar > 95 > Cooling System - Leaking Radiator Hose Joint > Page 2609 3. Pressure test the system again. If the leak persists, check the radiator hose clamp for damage. If damage is observed, replace the damaged part per the following installation steps. The clamps to be used are as shown. 4. If only the clamp is to be removed, residual glue (located 180° away from the tangs) may exist on the hose. The glue will generally dissipate over time with the thermal cycling of the engine. If necessary, remove the glued clamp by applying a heat gun at 420°F (21500) to the glued portion for approximately 1 minute. If any foreign material remains on (or if any material is removed from) the hose, a sealing discontinuity will result and the hose must be replaced. Proper installation of the hose and clamp is essential for the joint to be effective. The following steps should be taken to ensure a robust hose joint. ENSURING A ROBUST HOSE JOINT 1. Push the hose onto the connector until it is completely seated against the hose stop. 2. Release the "Mega" clamp by carefully removing the retaining clip using pliers or vise grips. During removal, the clip should be held securely at all times. Do not pry or pop the clip off the clamp. Application Chart 3. Check that the clamp is straight, fully released and seated on the sealing area of the hose and connector. The clamp should not be partially or completely cocked over or on top of the bead at the end of the connector. The connector, radiator hose and clamp are shown in Figure 1. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hose Clamp, Cooling System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose Clamp: > 95616 > Mar > 95 > Cooling System - Leaking Radiator Hose Joint > Page 2610 Parts Block NOTE: THE "MEGA" CLAMPS WERE SPECIFICALLY SIZED FOR 1995 AND LATER VEHICLES. THEY ARE NOT APPROPRIATE FOR VEHICLES BEFORE THE 1995 MODEL YEAR BECAUSE THE JOINT SEAL CONFIGURATION AND DIMENSIONS ARE DIFFERENT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950616A Pressure Test Cooling 0.3 Hr. System. Reseat Clamps As Required 950616B Additional Time To Replace 0.3 Hr. One (1) Clamp 950616C Additional Time To Replace 0.4 Hr. Two (2) Or More Clamps 950616D Additional Time To Replace 0.4 Hr. Upper Or Lower Radiator Hose 950616E Additional Time To Replace 0.5 Hr. Both Radiator Hoses DEALER CODING BASIC PART NO. CONDITION CODE 8287 33 OASIS CODES: 402000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation Fig. 8 Magnetic Guage The magnetic gauge movement consists of three primary coils, one of which is wound at a 90 degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet which is attached to a shaft and pointer rotates and aligns to this primary field resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which is attached to the instrument cluster. These gauges require no adjustments, calibrations or maintenance. This gauge system does not use an IVR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests Temperature Gauge: Pinpoint Tests Troubleshooting Chart, Temperature Gauge Inaccurate. Troubleshooting Chart, Temperature Gauge Inaccurate. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 2617 Temperature Gauge: Component Tests and General Diagnostics TROUBLESHOOTING Tester tool No. 021-00055 or equivalent should be used to diagnose these type of gauges. When troubleshooting, refer to pertaining pinpoint test. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Radiator - New Manufacturing Process Radiator: Technical Service Bulletins Radiator - New Manufacturing Process Article No. 95-2-4 01/30/95 COOLING SYSTEM - RADIATOR - NEW MANUFACTURING PROCESS ("CUTS" IN UPPER AND LOWER SUPPORTS) FORD: 1994 TEMPO 1994-95 ASPIRE, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1995 CONTOUR LINCOLN-MERCURY: 1994 TOPAZ 1994-95 CONTINENTAL, COUGAR, MARK VIII, SABLE, TOWN CAR, TRACER 1995 MYSTIQUE LIGHT TRUCK: 1994-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995 WINDSTAR ISSUE: A new radiator manufacturing process is currently being phased into production to provide longer radiator life. Part of the process change is to cut, lance or pierce the two (2) supports that connect the inlet and outlet tanks to relieve thermal stresses in the radiator. These cuts are located at the top and bottom of the radiator in the "U" shaped support. Refer to Figure 1. ACTION: Do not replace or return radiators because they appear to have the saw cuts in them. Those cuts are a design requirement. All cars and trucks will have saw cut radiators at some point during the 1994 and 1995 model years. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 2622 Radiator: Service and Repair REMOVAL AND INSTALLATION 1. Drain cooling system by removing radiator cap and opening draincock located at the lower rear corner of the radiator tank. Fig. 38 Radiator Replacement 2. Remove rubber radiator overflow hose from radiator coolant recovery reservoir and disconnect it from radiator. 3. Remove fan shroud attaching bolts. 4. Lift fan shroud back and drape it on fan. 5. Loosen upper and lower hose clamps at radiator and remove upper radiator hose and lower radiator from connectors. 6. Disconnect two automatic transmission oil cooling lines from radiator fittings, if equipped. 7. On models equipped with E4OD transmission, disconnect heated water bypass hose attached to lower tank. 8. Remove four radiator attaching bolts. 9. Tilt radiator back about one inch and lift upward, clear of radiator support. 10. Lift fan shroud off of fan and remove from vehicle. 11. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Relief Pressure .................................................................................................................................... .......................................................................... 13 psi Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation Engine Oil Temperature (EOT) Sensor: Description and Operation Engine Oil Temperature Sensor The Engine Oil Temperature (EOT) sensor changes resistance in response to changing temperature of the engine oil. The engine oil temperature sensor resistance decreases as the engine oil temperature increases providing a signal to the Powertrain Control Module (PCM), indicating the temperature of the engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation > Page 2634 Engine Oil Temperature (EOT) Sensor: Service and Repair REMOVAL 1. Disconnect engine oil temperature sensor electrical connector. 2. Approximately 0.94 liters (one quart) of engine oil must be removed prior to sensor removal. Remove one quart of engine oil from high pressure oil pump reservoir using Rotunda Vacuum Tester 014-R1058 or equivalent. 3. Remove engine oil temperature sensor. INSTALLATION 1. Install engine oil temperature sensor. 2. Connect engine oil temperature sensor electrical connector. 3. Fill engine oil to proper level. 4. Refill oil pump reservoir with engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic Engine Coolant Temperature Sender: Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic > Page 2639 6. In the Remarks Section, write "Returned per TSB 95-13-2". 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 FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation Fig. 8 Magnetic Guage The magnetic gauge movement consists of three primary coils, one of which is wound at a 90 degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet which is attached to a shaft and pointer rotates and aligns to this primary field resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which is attached to the instrument cluster. These gauges require no adjustments, calibrations or maintenance. This gauge system does not use an IVR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests Temperature Gauge: Pinpoint Tests Troubleshooting Chart, Temperature Gauge Inaccurate. Troubleshooting Chart, Temperature Gauge Inaccurate. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 2645 Temperature Gauge: Component Tests and General Diagnostics TROUBLESHOOTING Tester tool No. 021-00055 or equivalent should be used to diagnose these type of gauges. When troubleshooting, refer to pertaining pinpoint test. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair Thermostat: Service and Repair Thermostat Assembly REMOVAL 1. Drain the cooling system. 2. Remove the air cleaner housing assembly. 3. Disconnect the drive belt (8620) at the drive belt tensioner pulley. 4. Remove the upper radiator hose clamp at the water pump outlet and disconnect the upper radiator hose (8260) from the water pump outlet. 5. Remove retaining screws and the water outlet connection. 6. Remove the water hose connection gasket (8255) and water thermostat (8575). INSTALLATION 1. Install the water thermostat and the water hose connection gasket in the water pump outlet. 2. Install the water pump outlet and install water pump outlet retaining screws. Tighten screws to 20 Nm (15 ft. lb.). 3. Connect the upper radiator hose to the water pump outlet and install hose clamp. 4. Install the drive belt at the drive belt tensioner pulley. 5. Refill and bleed the engine cooling system. 6. Install the air cleaner housing assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair REMOVAL 1. Partially drain the engine cooling system. 2. Remove the air cleaner housing assembly. 3. Remove the upper radiator hose clamps and upper radiator hose (8260). 4. Disconnect the radiator coolant recovery reservoir hose at radiator (8005). 5. Remove the fan and clutch assembly using Fan Clutch Nut Wrench T83T-6312-B and Fan Clutch Pulley Holder T94T-6312-AH. Set fan and clutch assembly in fan shroud (8146). NOTE: the fan clutch assembly has right-hand thread. Install by turning nut clockwise. 6. Remove the fan shroud screws. 7. Remove the fan shroud, and fan and clutch assembly. 8. Loosen the water pump pulley bolts. 9. Remove the drive belt (8620). 10. Remove the water pump pulley bolts and water pump pulley (8509). 11. Disconnect the engine coolant temperature sensor (ECT sensor) (12A648). 12. Disconnect the heater hose and clamp from water pump. 13. Disconnect the engine coolant temperature sensor electrical connector. 14. Remove the water pump inlet bolts and water pump inlet. 15. Remove water pump bolts. 16. Remove water pump and water pump housing gasket (8507). 17. Clean gasket surfaces. Water Pump INSTALLATION 1. Install the water pump and water pump housing gasket. 2. Install the water pump bolts, tighten bolts to 20 Nm (15 ft lb). 3. Install the water pump inlet and bolts, tighten bolts to 20 Nm (15 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Page 2652 4. Connect the engine coolant temperature sensor electrical connector. 5. Install the heater hose and clamp to the water pump. 6. Connect the engine coolant temperature sensor. 7. Install the water pump pulley and start the water pump pulley bolts. 8. Install the drive belt. 9. Tighten the water pump pulley bolts to 16-24 Nm (12-18 ft. lb.). 10. Install the fan shroud, and fan and clutch assembly. 11. Install the fan shroud screws. 12. Install the fan and clutch assembly using Fan Clutch Nut Wrench T83T-6312-B and Fan Clutch Pulley Holder T94T-6312-AH. NOTE: The fan clutch assembly has right-hand thread. Install by turning nut clockwise. 13. Install the radiator coolant recovery reservoir hose to radiator. 14. Install the upper radiator hose and clamps. 15. Install the air cleaner housing assembly. 16. Refill and bleed the engine cooling system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2663 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2664 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2670 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2671 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise Heat Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 2680 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 2681 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Heat Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2687 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2688 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-24 > Oct > 03 > Engine Control - Cold Temperature Hard Start/No Start Powertrain Control Module: Customer Interest Engine Control - Cold Temperature Hard Start/No Start Article No. 03-21-24 10/06/03 HARD START/NO START - EXTREME COLD AMBIENT TEMPERATURE - VEHICLES WITH 7.3L DIESEL ENGINE FORD: 1992-1996 ECONOLINE Article 97-7-7 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A hard start or no start condition in extreme cold weather may occur on some vehicles. This may be caused by fuel freezing in the delivery module draw tube. ACTION Replace Diesel Delivery Module (DDM) with a revised DDM (-9275-). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. NOTE WHEN REPLACING THE DDM, BE SURE TO CLEAN AREA AROUND FLANGE/TANK OPENING TO PREVENT PARTICULATE MATTER FROM FALLING INTO THE FUEL TANK. 2. Replace the DDM with the revised DDM (-9275-) by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. 3. Reinstall the fuel tank. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-7 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 03-21-24 > Oct > 03 > Engine Control - Cold Temperature Hard Start/No Start Powertrain Control Module: All Technical Service Bulletins Engine Control - Cold Temperature Hard Start/No Start Article No. 03-21-24 10/06/03 HARD START/NO START - EXTREME COLD AMBIENT TEMPERATURE - VEHICLES WITH 7.3L DIESEL ENGINE FORD: 1992-1996 ECONOLINE Article 97-7-7 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A hard start or no start condition in extreme cold weather may occur on some vehicles. This may be caused by fuel freezing in the delivery module draw tube. ACTION Replace Diesel Delivery Module (DDM) with a revised DDM (-9275-). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. NOTE WHEN REPLACING THE DDM, BE SURE TO CLEAN AREA AROUND FLANGE/TANK OPENING TO PREVENT PARTICULATE MATTER FROM FALLING INTO THE FUEL TANK. 2. Replace the DDM with the revised DDM (-9275-) by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. 3. Reinstall the fuel tank. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-7 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99-4-3 > Mar > 99 > PCM Reprogramming Out of Vehicle Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99-4-3 > Mar > 99 > PCM Reprogramming Out of Vehicle > Page 2709 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 97-9-8 > Apr > 97 > PCM Reprogramming Tips Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 97-9-8 > Apr > 97 > PCM Reprogramming Tips > Page 2714 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 99-4-3 > Mar > 99 > PCM Reprogramming Out of Vehicle Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 99-4-3 > Mar > 99 > PCM Reprogramming Out of Vehicle > Page 2720 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 97-9-8 > Apr > 97 > PCM Reprogramming Tips Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 97-9-8 > Apr > 97 > PCM Reprogramming Tips > Page 2725 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2726 Powertrain Control Module: Specifications PCM Retainer Nuts 3-4 Nm Wiring Connector Retaining Bolts 4 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 2727 Powertrain Control Module: Locations Engine Compartment View The Powertrain Control Module is located at the left rear of the engine compartment, near brake master cylinder. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2730 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2731 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2732 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2733 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2734 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2735 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2736 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2737 Powertrain Control Module: Connector Views Powertrain Control Module (Part 1 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2738 Powertrain Control Module (Part 2 Of 2) PCM Pinout Chart PCM Pinout Chart Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2739 PCM Pinout (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2740 Part 2 Of 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2741 Part 3 Of 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2742 Part 4 Of 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2743 Powertrain Control Module: Description and Operation Powertrain Control Module (PCM) The Powertrain Control Module (PCM) retrieves inputs from various engine sensors to compute the required fuel flow rate necessary to maintain a proper air/fuel ratio throughout the entire engine operational range. The PCM also determines and compensates the vehicle's uniqueness. The system will also compensate for changes in altitude (i.e., from sea level to mountains). The 104-pin EEC-V system PCM outputs a command to the Injector Driver Module (IDM) which in turn energizes the fuel injector with up to 115V DC. The fuel injector is controlled by the in IDM to meter the appropriate quantity of fuel at the correct time and duration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2744 Powertrain Control Module: Service and Repair Powertrain Control Module REMOVAL 1. Disconnect battery negative cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Loosen engine control sensor wiring to PCM connector retainer bolt. 3. Remove engine control sensor wiring connector from PCM. 4. Remove the two PCM seal nuts and loosen left fender liner screws and remove liner or bend down to clear powertrain control module. Remove PCM. INSTALLATION 1. Follow removal procedures in reverse order. 2. Tighten PCM retainer screw to 3-4 Nm (27-35 in lb). Tighten engine control sensor wiring connector retainer bolt to 4 Nm (35 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Injector Driver Module > Component Information > Specifications Injector Driver Module: Specifications Injector Driver Module Retaining Bolt 3-4 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 2748 Injector Driver Module: Locations Engine Compartment View The Injector Driver Module is located at the LH rear of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 2749 Injector Driver Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 2750 Injector Driver Module: Service Precautions WARNING: RED-STRIPED WIRES CARRY 115V DC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 2751 Injector Driver Module: Description and Operation The Injector Driver Module (IDM) supplies 115V DC to all of the fuel injectors. The IDM receives signals from the Powertrain Control Module (PCM) for Cylinder Identification (CID) and Fuel Delivery Command Signal (FDCS). The PCM controls when the timing of the injectors should start and how long the injector is open. The IDM controls the injector firing sequence through output drivers. The IDM has an output driver for each injector: one low side driver for each injector and one high side driver for each bank of injectors. The injector is fired when the output driver closes the circuit to ground, completing the circuit ground path. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 2752 Injector Driver Module: Service and Repair REMOVAL WARNING: RED-STRIPED WIRES CARRY 115V DC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. 1. Disconnect battery negative cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Remove module bolts. 3. Loosen wiring connector retainer bolt. 4. Remove Injector Driver Module (IDM). INSTALLATION 1. To install, reverse removal procedures. 2. Tighten IDM retainer bolt to 3-4 Nm (27-35 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Injector Driver Module Relay > Component Information > Description and Operation Injector Driver Module Relay: Description and Operation PURPOSE The Injector Driver Module (IDM) Relay provides power to the IDM. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Control Unit: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 2761 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 2762 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 2763 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 2764 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 2765 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 2766 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 2767 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Customer Interest for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition Glow Plug Relay: Customer Interest Diesel Engine - Hard Start/No Start Condition Article No. 96-1-7 01/02/96 ^ HARD START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ NO START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ ENGINE - 7.3L DIT DIESEL - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 LIGHT TRUCK: 1994-95 F SUPER DUTY, F-25O, F-35O 1995 E-35O ISSUE: The glow plug relay may melt and result in a no start/hard start condition. This may be caused by the nuts on the glow plug relay losing their torque and increasing the resistance on the connections of the relay. ACTION: Increase the torque of the nuts on the glow plug relay and add a lockwasher. Refer to the following Service Procedure for details. NOTE: THIS PROCEDURE SHOULD BE ADHERED TO FOR ALL FUTURE GLOW PLUG REPAIRS ON 7.3L DIT DIESEL ENGINES. SERVICE PROCEDURE CAUTION: DO NOT USE A SCREWDRIVER OR SIMILAR TOOL TO PRY OFF THE TERMINAL COVER. BATTERY VOLTAGE IS PRESENT AT THE TERMINALS. 1. Disconnect the batteries. 2. Remove the glow plug relay plastic terminal cover. 3. Remove glow plug relay nuts. 4. Add zinc plated lockwashers (34791-S36) on top of the wire harness connectors below the upper nuts. CAUTION: ZINC PLATED LOCKWASHERS MUST BE USED. 5. Replace nuts and torque to 7.9 t0.6 N-m (70 +/- 5 lb-in). CAUTION: DO NOT OVERTORQUE. DAMAGE TO THE RELAY WILL RESULT. 6. With the addition of the lockwasher, the plastic terminal cover may not remain securely attached to the studs. Therefore, apply Silastic Sealer (F4AZ-19562-B) to the plastic terminal cover to make sure the cover remains secure. Replace the cover. 7. Reconnect the batteries. PART NUMBER PART NAME 34791-536 Zinc Plated Lockwasher F4AZ-19562-B Silastic Sealer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960107A Install Lockwashers And 0.4 Hr. Apply Increased Torque DEALER CODING Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Customer Interest for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition > Page 2777 CONDITION BASIC PART NO. CODE 12B533 H4 OASIS CODES: 203000, 203200, 601300, 602300, 603300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition Glow Plug Relay: All Technical Service Bulletins Diesel Engine - Hard Start/No Start Condition Article No. 96-1-7 01/02/96 ^ HARD START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ NO START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ ENGINE - 7.3L DIT DIESEL - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 LIGHT TRUCK: 1994-95 F SUPER DUTY, F-25O, F-35O 1995 E-35O ISSUE: The glow plug relay may melt and result in a no start/hard start condition. This may be caused by the nuts on the glow plug relay losing their torque and increasing the resistance on the connections of the relay. ACTION: Increase the torque of the nuts on the glow plug relay and add a lockwasher. Refer to the following Service Procedure for details. NOTE: THIS PROCEDURE SHOULD BE ADHERED TO FOR ALL FUTURE GLOW PLUG REPAIRS ON 7.3L DIT DIESEL ENGINES. SERVICE PROCEDURE CAUTION: DO NOT USE A SCREWDRIVER OR SIMILAR TOOL TO PRY OFF THE TERMINAL COVER. BATTERY VOLTAGE IS PRESENT AT THE TERMINALS. 1. Disconnect the batteries. 2. Remove the glow plug relay plastic terminal cover. 3. Remove glow plug relay nuts. 4. Add zinc plated lockwashers (34791-S36) on top of the wire harness connectors below the upper nuts. CAUTION: ZINC PLATED LOCKWASHERS MUST BE USED. 5. Replace nuts and torque to 7.9 t0.6 N-m (70 +/- 5 lb-in). CAUTION: DO NOT OVERTORQUE. DAMAGE TO THE RELAY WILL RESULT. 6. With the addition of the lockwasher, the plastic terminal cover may not remain securely attached to the studs. Therefore, apply Silastic Sealer (F4AZ-19562-B) to the plastic terminal cover to make sure the cover remains secure. Replace the cover. 7. Reconnect the batteries. PART NUMBER PART NAME 34791-536 Zinc Plated Lockwasher F4AZ-19562-B Silastic Sealer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960107A Install Lockwashers And 0.4 Hr. Apply Increased Torque DEALER CODING Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition > Page 2783 CONDITION BASIC PART NO. CODE 12B533 H4 OASIS CODES: 203000, 203200, 601300, 602300, 603300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Page 2784 Glow Plug Relay: Locations Glow Plug Relay The glow plug relay is mounted on top of the engine, behind the generator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Page 2785 Glow Plug Relay: Description and Operation DESCRIPTION The glow plug control module has a plastic base and two mounting bolts. It is operated by the Powertrain Control Module (PCM) which senses engine oil temperature, PCM voltage, and barometric pressure. OPERATION When the engine oil temperature or the barometric pressure is low, the PCM activates the glow plug control module and the intake manifold glow plugs. If the PCM voltage is too high, the PCM deactivates the glow plug control module and the intake manifold glow plugs immediately energize for a shorter duration, decreasing the modulation of the duty cycle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Page 2786 Glow Plug Relay: Service and Repair REMOVAL 1. Disconnect the batteries. 2. Remove the plastic terminal cover from the relay. CAUTION: Do not use a screwdriver or similar tool to pry off the terminal cover. Battery voltage is present at the terminals. 3. Disconnect the battery terminal connector (12 volt power wire), the glow plug relay connector, and the harness connector. 4. Remove the mounting screws and remove the relay from the engine. INSTALLATION 1. Install the relay on the engine and tighten the screws. 2. Reconnect the harness connector, relay connector, and the battery terminal connector. 3. Reinstall the plastic terminal cover. 4. Reconnect the batteries. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement Technical Service Bulletin # 94E52 Date: 950201 Recall - Ignition Control Module Inspection/Replacement 94E52 EMISSIONS RECALL Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Dealer Letter Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Customer Notification Letter Attachment I - Administrative Instructions Administrative Instructions OASIS You must use OASIS to determine if a truck is eligible for this or another recall. Note Correct all affected dealer stock trucks before delivery. Promptly Correct Affected trucks on the enclosed list and other eligible trucks on hand or brought to your dealership. Dealer Owner Contact Immediately contact any owner of an eligible truck you know of whose name is not on the list. Give the owner a copy of the Owner Letter. Region Contact Advise FCSD regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Parts and Service Zone Manager about recall concerns. Claims Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use a Form 1863 or authorized alternative claim form as an internal repair order to support your DWE entry. Please read Section 6.3 of your Warranty and Policy Manual. This section contains claim processing information including related damage/refunds and refunds. Attachment II - Labor and Parts Information Labor Allowance Inspect the Ignition Control (IC) Module for Build Date and, if necessary, Replace the Module. Obtain, Prepare and Attach an Authorized Modifications Label. Provided California Owners With "Emissions Recall - Proof of Correction" Certificates. Claim Procedure For Dealers Not On ACES II Pilot INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2796 F-Series 0.2 Hrs. Insert in Box "A" on Form 1864 Econoline 0.4 Hrs. Insert in Box "A" on Form 1864 INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Insert in Box "B" on Form 1864 Econoline 0.5 Hrs. Insert in Box "B" on Form 1864 Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Claim Procedure for Dealers on ACES II Pilot Submit using DWE INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.2 Hrs. Labor Operation - 94E52A Econoline 0.4 Hrs. Labor Operation - 94E52A 0.1 Hrs. Misc. Expense Code "ADMIN" INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Labor Operation - 94E52B Econoline 0.5 Hrs. Labor Operation - 94E52B 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. Part Number Description F1PZ-12A297-A Module, Ignition Control (IC) For the latest part price, call or check ^ Order Processing Center ^ an updated Master Price Book ^ DOESII Excess Stock Return Excess stock returned for credit must have been purchased form Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ignition Control (IC) Module Inspection And Replacement Affected Vehicles: 1995 Model E and F-Series Trucks as follows: Kentucky Truck Plant 11/23 Thru 28, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2797 Lorain Assembly 11/22 Thru 28, 1994 Norfolk Assembly 11/22 Thru 29, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2798 1. Locate ignition control module under hood. On F-Series models, it is located on the left inner fender panel near the hood hinge. See Figure 1. On E-Series models, it is located behind the battery on the dash panel. See Figure 2. 2. On Econoline models only, disconnect and position battery out of the way. 3. Remove two screws retaining ignition control module heat-sink assembly to left fender apron. 4. Disconnect harness connector from ignition control module. 5. Inspect date code on module. If the date code is 4L18B, the module must be replaced. See Figure 3 for date code location. Continue on to next step. If not, go to step 9. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2799 6. Remove two screws retaining ignition control module to heat-sink and remove ignition control module. 7. Coat metal baseplate of the replacement ignition control module uniformly with silicone compound, approximately .0179 mm (1/31-inch) thick. Use Silicone Dielectric Compound WA-10 D7AZ-19A331-A (ESE-M1C171-A) or equivalent. 8. Position ignition control module onto heat-sink and tighten two retaining screws to 1.7-4.0 N-m (15-35 in-lb). 9. Install ignition control module heat-sink assembly useing two retaining screws, and tighten to 9-14 N-m (80-124 in-lb). 10. Connect engine control sensor wiring to the ignition control module. 11. On Econoline models only, reposition and connect battery. Start engine, verify operation. Authorized Modifications Labels And California "Emissions Recall-Proof of Corrections" Certificates ^ Obtain, prepare and attach an Authorized Modifications Label (available at no-charge {package of 25 with overlay} as part number FCS-8262 or DOES II). Write on the label "IC Module Inspected/Replaced", authority, Emissions Recall 94E52", your P&A; Code and date of repair as shown below. ^ Provide California owners with "Emissions Recall-Proof of Correction " Certificates. Authorized Modifications Decal Dealer Letter RECALL NUMBER 94E52 Date: Feb., 1995 PARTS AVAILABILITY At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers At PDC By: Now Date in Owner Letter: March, 1995 To: All Dealers Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2800 Subject: Emissions Recall 94E52 - Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Affected Vehicles Approximately 4,500 1995-model E & F-Series trucks manufactured at the Kentucky Truck Plant November 23 through 28, 1994, the Lorain Assembly Plant from November 22, through 28, 1994, and the Norfolk Assembly Plant from November 22, through 29, 1994. Reasons For Recall Some of these trucks have been built and shipped with ignition control (IC) modules which may fail and cause an engine no-start condition. Service Action The IC module will be inspected for build date and, if necessary, will be replaced. Attachments Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Owner Letter March, 1995 Serial Number: 12345678901234567 94E52 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 94E52) certain 1995-Model Econoline and F-Series Trucks. Your truck may have been manufactured with an ignition control module that may fail and cause an engine no-start condition. What The Dealer Will Do At no cost to you, your dealer will inspect the ignition control module on your truck and, if necessary, replace the module. If you do not have this service done, your Emissions Warranty may be reduced. How Long Will It Take? The time needed to repair your truck is about one-half hour. However, due to service scheduling times, your dealer may need your truck one full working day. Call Your Dealer Call your Dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When your bring your truck in, present this letter to the dealer. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address or Sold the Truck? If you have, please fill out the enclosed prepaid postcard and mail it to us. If the service for this recall is not provided promptly and without charge, talk to the dealer service manager. You may also contact the Ford Customer Assistance Center at 300 Renaissance Center, P.O. Box 43360, Detroit, MI, 48243. Please have your truck serviced promptly to maintain full Emissions warranty coverage. We regret the inconvenience this recall may cause you. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9599 > May > 95 > Thermactor System - Buzzing Noise AIRB Solenoid: All Technical Service Bulletins Thermactor System - Buzzing Noise Article No. 95-9-9 05/08/95 ^ THERMACTOR SYSTEM - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY ^ NOISE - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - THERMACTOR SYSTEM OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY LIGHT TRUCK: 1994-95 E-350 ISSUE: A "buzzing" noise may be heard between 25-40 mph while in 2nd or 3rd gear. This may be caused by air flow through the thermactor system during operation in dump mode. ACTION: Replace the air supply bypass valve hose with a cap on the intake air duct and install a thermactor silencer and bracket assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the air dump hose which connects the thermactor bypass valve to the fresh air intake air duct. 2. Cap the open nipple on the intake air duct with a Rubber Cap (C6AZ-9486-A). No clamps are necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 2806 3. Install one (1) end of the Air Supply Pump Silencer Hose (F4TZ-9H458-A) onto the Silencer and Bracket Assembly (F4TZ-9H467-B) and secure with a Crimp Clamp (F1HZ-9H447-AA). Refer to Figure 1. 4. Remove the bolt from the engine installed thermactor assembly and install silencer and hose assembly. Refer to Figure 1. 5. Reinstall the bolt and torque to 11-19 N-m (8-14 lb.ft.). No clamp is necessary at the end of the hose. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 2807 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950909A Replace Air Dump Hose 0.4 Hr. With Cap And Install Silencer Assembly DEALER CODING CONDITION BASIC PART NO. CODE 9F870 56 OASIS CODES: 403000, 702000, 702300, 703000, 703300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 9599 > May > 95 > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement Technical Service Bulletin # 94E52 Date: 950201 Recall - Ignition Control Module Inspection/Replacement 94E52 EMISSIONS RECALL Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Dealer Letter Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Customer Notification Letter Attachment I - Administrative Instructions Administrative Instructions OASIS You must use OASIS to determine if a truck is eligible for this or another recall. Note Correct all affected dealer stock trucks before delivery. Promptly Correct Affected trucks on the enclosed list and other eligible trucks on hand or brought to your dealership. Dealer Owner Contact Immediately contact any owner of an eligible truck you know of whose name is not on the list. Give the owner a copy of the Owner Letter. Region Contact Advise FCSD regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Parts and Service Zone Manager about recall concerns. Claims Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use a Form 1863 or authorized alternative claim form as an internal repair order to support your DWE entry. Please read Section 6.3 of your Warranty and Policy Manual. This section contains claim processing information including related damage/refunds and refunds. Attachment II - Labor and Parts Information Labor Allowance Inspect the Ignition Control (IC) Module for Build Date and, if necessary, Replace the Module. Obtain, Prepare and Attach an Authorized Modifications Label. Provided California Owners With "Emissions Recall - Proof of Correction" Certificates. Claim Procedure For Dealers Not On ACES II Pilot INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 9599 > May > 95 > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2817 F-Series 0.2 Hrs. Insert in Box "A" on Form 1864 Econoline 0.4 Hrs. Insert in Box "A" on Form 1864 INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Insert in Box "B" on Form 1864 Econoline 0.5 Hrs. Insert in Box "B" on Form 1864 Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Claim Procedure for Dealers on ACES II Pilot Submit using DWE INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.2 Hrs. Labor Operation - 94E52A Econoline 0.4 Hrs. Labor Operation - 94E52A 0.1 Hrs. Misc. Expense Code "ADMIN" INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Labor Operation - 94E52B Econoline 0.5 Hrs. Labor Operation - 94E52B 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. Part Number Description F1PZ-12A297-A Module, Ignition Control (IC) For the latest part price, call or check ^ Order Processing Center ^ an updated Master Price Book ^ DOESII Excess Stock Return Excess stock returned for credit must have been purchased form Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ignition Control (IC) Module Inspection And Replacement Affected Vehicles: 1995 Model E and F-Series Trucks as follows: Kentucky Truck Plant 11/23 Thru 28, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 9599 > May > 95 > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2818 Lorain Assembly 11/22 Thru 28, 1994 Norfolk Assembly 11/22 Thru 29, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 9599 > May > 95 > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2819 1. Locate ignition control module under hood. On F-Series models, it is located on the left inner fender panel near the hood hinge. See Figure 1. On E-Series models, it is located behind the battery on the dash panel. See Figure 2. 2. On Econoline models only, disconnect and position battery out of the way. 3. Remove two screws retaining ignition control module heat-sink assembly to left fender apron. 4. Disconnect harness connector from ignition control module. 5. Inspect date code on module. If the date code is 4L18B, the module must be replaced. See Figure 3 for date code location. Continue on to next step. If not, go to step 9. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 9599 > May > 95 > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2820 6. Remove two screws retaining ignition control module to heat-sink and remove ignition control module. 7. Coat metal baseplate of the replacement ignition control module uniformly with silicone compound, approximately .0179 mm (1/31-inch) thick. Use Silicone Dielectric Compound WA-10 D7AZ-19A331-A (ESE-M1C171-A) or equivalent. 8. Position ignition control module onto heat-sink and tighten two retaining screws to 1.7-4.0 N-m (15-35 in-lb). 9. Install ignition control module heat-sink assembly useing two retaining screws, and tighten to 9-14 N-m (80-124 in-lb). 10. Connect engine control sensor wiring to the ignition control module. 11. On Econoline models only, reposition and connect battery. Start engine, verify operation. Authorized Modifications Labels And California "Emissions Recall-Proof of Corrections" Certificates ^ Obtain, prepare and attach an Authorized Modifications Label (available at no-charge {package of 25 with overlay} as part number FCS-8262 or DOES II). Write on the label "IC Module Inspected/Replaced", authority, Emissions Recall 94E52", your P&A; Code and date of repair as shown below. ^ Provide California owners with "Emissions Recall-Proof of Correction " Certificates. Authorized Modifications Decal Dealer Letter RECALL NUMBER 94E52 Date: Feb., 1995 PARTS AVAILABILITY At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers At PDC By: Now Date in Owner Letter: March, 1995 To: All Dealers Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 9599 > May > 95 > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2821 Subject: Emissions Recall 94E52 - Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Affected Vehicles Approximately 4,500 1995-model E & F-Series trucks manufactured at the Kentucky Truck Plant November 23 through 28, 1994, the Lorain Assembly Plant from November 22, through 28, 1994, and the Norfolk Assembly Plant from November 22, through 29, 1994. Reasons For Recall Some of these trucks have been built and shipped with ignition control (IC) modules which may fail and cause an engine no-start condition. Service Action The IC module will be inspected for build date and, if necessary, will be replaced. Attachments Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Owner Letter March, 1995 Serial Number: 12345678901234567 94E52 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 94E52) certain 1995-Model Econoline and F-Series Trucks. Your truck may have been manufactured with an ignition control module that may fail and cause an engine no-start condition. What The Dealer Will Do At no cost to you, your dealer will inspect the ignition control module on your truck and, if necessary, replace the module. If you do not have this service done, your Emissions Warranty may be reduced. How Long Will It Take? The time needed to repair your truck is about one-half hour. However, due to service scheduling times, your dealer may need your truck one full working day. Call Your Dealer Call your Dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When your bring your truck in, present this letter to the dealer. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address or Sold the Truck? If you have, please fill out the enclosed prepaid postcard and mail it to us. If the service for this recall is not provided promptly and without charge, talk to the dealer service manager. You may also contact the Ford Customer Assistance Center at 300 Renaissance Center, P.O. Box 43360, Detroit, MI, 48243. Please have your truck serviced promptly to maintain full Emissions warranty coverage. We regret the inconvenience this recall may cause you. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for AIRB Solenoid: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement Technical Service Bulletin # 94E52 Date: 950201 Recall - Ignition Control Module Inspection/Replacement 94E52 EMISSIONS RECALL Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Dealer Letter Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Customer Notification Letter Attachment I - Administrative Instructions Administrative Instructions OASIS You must use OASIS to determine if a truck is eligible for this or another recall. Note Correct all affected dealer stock trucks before delivery. Promptly Correct Affected trucks on the enclosed list and other eligible trucks on hand or brought to your dealership. Dealer Owner Contact Immediately contact any owner of an eligible truck you know of whose name is not on the list. Give the owner a copy of the Owner Letter. Region Contact Advise FCSD regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Parts and Service Zone Manager about recall concerns. Claims Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use a Form 1863 or authorized alternative claim form as an internal repair order to support your DWE entry. Please read Section 6.3 of your Warranty and Policy Manual. This section contains claim processing information including related damage/refunds and refunds. Attachment II - Labor and Parts Information Labor Allowance Inspect the Ignition Control (IC) Module for Build Date and, if necessary, Replace the Module. Obtain, Prepare and Attach an Authorized Modifications Label. Provided California Owners With "Emissions Recall - Proof of Correction" Certificates. Claim Procedure For Dealers Not On ACES II Pilot INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for AIRB Solenoid: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2827 F-Series 0.2 Hrs. Insert in Box "A" on Form 1864 Econoline 0.4 Hrs. Insert in Box "A" on Form 1864 INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Insert in Box "B" on Form 1864 Econoline 0.5 Hrs. Insert in Box "B" on Form 1864 Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Claim Procedure for Dealers on ACES II Pilot Submit using DWE INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.2 Hrs. Labor Operation - 94E52A Econoline 0.4 Hrs. Labor Operation - 94E52A 0.1 Hrs. Misc. Expense Code "ADMIN" INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Labor Operation - 94E52B Econoline 0.5 Hrs. Labor Operation - 94E52B 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. Part Number Description F1PZ-12A297-A Module, Ignition Control (IC) For the latest part price, call or check ^ Order Processing Center ^ an updated Master Price Book ^ DOESII Excess Stock Return Excess stock returned for credit must have been purchased form Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ignition Control (IC) Module Inspection And Replacement Affected Vehicles: 1995 Model E and F-Series Trucks as follows: Kentucky Truck Plant 11/23 Thru 28, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for AIRB Solenoid: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2828 Lorain Assembly 11/22 Thru 28, 1994 Norfolk Assembly 11/22 Thru 29, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for AIRB Solenoid: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2829 1. Locate ignition control module under hood. On F-Series models, it is located on the left inner fender panel near the hood hinge. See Figure 1. On E-Series models, it is located behind the battery on the dash panel. See Figure 2. 2. On Econoline models only, disconnect and position battery out of the way. 3. Remove two screws retaining ignition control module heat-sink assembly to left fender apron. 4. Disconnect harness connector from ignition control module. 5. Inspect date code on module. If the date code is 4L18B, the module must be replaced. See Figure 3 for date code location. Continue on to next step. If not, go to step 9. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for AIRB Solenoid: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2830 6. Remove two screws retaining ignition control module to heat-sink and remove ignition control module. 7. Coat metal baseplate of the replacement ignition control module uniformly with silicone compound, approximately .0179 mm (1/31-inch) thick. Use Silicone Dielectric Compound WA-10 D7AZ-19A331-A (ESE-M1C171-A) or equivalent. 8. Position ignition control module onto heat-sink and tighten two retaining screws to 1.7-4.0 N-m (15-35 in-lb). 9. Install ignition control module heat-sink assembly useing two retaining screws, and tighten to 9-14 N-m (80-124 in-lb). 10. Connect engine control sensor wiring to the ignition control module. 11. On Econoline models only, reposition and connect battery. Start engine, verify operation. Authorized Modifications Labels And California "Emissions Recall-Proof of Corrections" Certificates ^ Obtain, prepare and attach an Authorized Modifications Label (available at no-charge {package of 25 with overlay} as part number FCS-8262 or DOES II). Write on the label "IC Module Inspected/Replaced", authority, Emissions Recall 94E52", your P&A; Code and date of repair as shown below. ^ Provide California owners with "Emissions Recall-Proof of Correction " Certificates. Authorized Modifications Decal Dealer Letter RECALL NUMBER 94E52 Date: Feb., 1995 PARTS AVAILABILITY At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers At PDC By: Now Date in Owner Letter: March, 1995 To: All Dealers Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for AIRB Solenoid: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 2831 Subject: Emissions Recall 94E52 - Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Affected Vehicles Approximately 4,500 1995-model E & F-Series trucks manufactured at the Kentucky Truck Plant November 23 through 28, 1994, the Lorain Assembly Plant from November 22, through 28, 1994, and the Norfolk Assembly Plant from November 22, through 29, 1994. Reasons For Recall Some of these trucks have been built and shipped with ignition control (IC) modules which may fail and cause an engine no-start condition. Service Action The IC module will be inspected for build date and, if necessary, will be replaced. Attachments Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Owner Letter March, 1995 Serial Number: 12345678901234567 94E52 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 94E52) certain 1995-Model Econoline and F-Series Trucks. Your truck may have been manufactured with an ignition control module that may fail and cause an engine no-start condition. What The Dealer Will Do At no cost to you, your dealer will inspect the ignition control module on your truck and, if necessary, replace the module. If you do not have this service done, your Emissions Warranty may be reduced. How Long Will It Take? The time needed to repair your truck is about one-half hour. However, due to service scheduling times, your dealer may need your truck one full working day. Call Your Dealer Call your Dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When your bring your truck in, present this letter to the dealer. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address or Sold the Truck? If you have, please fill out the enclosed prepaid postcard and mail it to us. If the service for this recall is not provided promptly and without charge, talk to the dealer service manager. You may also contact the Ford Customer Assistance Center at 300 Renaissance Center, P.O. Box 43360, Detroit, MI, 48243. Please have your truck serviced promptly to maintain full Emissions warranty coverage. We regret the inconvenience this recall may cause you. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Engine Control - Poor Acceleration Response Accelerator Pedal Position Sensor: Technical Service Bulletins Engine Control - Poor Acceleration Response Article No. 03-21-6 10/06/03 DRIVEABILITY - ACCELERATOR PEDAL - LACK OF ACCELERATOR CONTROL WHEN MOVING FROM IDLE POSITION - POOR OR NO ENGINE RESPONSE - 7.3L DIT FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 95-10-10 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A lack of accelerator control when moving off of the idle position may occur on some vehicles. The vehicle's engine will be at idle RPM only. This may be caused by the Idle Validation Switch (IVS) contacts not properly closing due to interference of contacts with the switch housing. ACTION Remove and install a revised accelerator pedal assembly which includes IVS. Refer to the appropriate year 7.3L Turbo Diesel Service Manual Supplement, Pages 10-02-2 and 10-02-3, for service procedures. NOTE THE IVS DATE OF MANUFACTURE IS STAMPED NEAR ITS CONNECTOR MATING SURFACE. THE DATE CODE READS AS FOLLOWS: TWO (2) DIGITS FOR CALENDAR YEAR, FOLLOWED BY TWO (2) DIGITS FOR WEEK OF CALENDAR YEAR WHEN MANUFACTURED. FOR EXAMPLE: 9503 INDICATES SWITCH MADE THE THIRD WEEK OF 1995. NOTE ALL SWITCHES WITH A DATE CODE OF 9510 AND LATER HAVE THE CORRECTED SWITCH HOUSING. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-10-10 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 2838 Accelerator Pedal Position Sensor: Specifications Accelerator Pedal Position Sensor 22-28 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 2839 Accelerator Pedal Position Sensor: Locations Full Body View (Part 3 Of 3) The Accelerator Pedal Position Sensor is located behind LH side of instrument panel, above accelerator pedal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor: Description and Operation Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor The Accelerator Pedal (AP) position sensor is a potentiometer that provides a signal to the Powertrain Control Module (PCM) proportional to the accelerator pedal position. The AP position sensor connects to the accelerator pedal shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor > Page 2842 Accelerator Pedal Position Sensor: Description and Operation Idle Validation Switch The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 2843 Accelerator Pedal Position Sensor: Adjustments The Accelerator Pedal (AP) position sensor cannot be adjusted. If service is required, replace accelerator pedal and shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 2844 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor CAUTION: The accelerator pedal assembly is a calibrated unit and must be handled with care. REMOVAL 1. Disconnect the electrical connectors from the Idle Validation Switch (IVS) and the Accelerator Pedal Position (AP) sensor. 2. remove the bolts holding the accelerator pedal and shaft to the instrument panel, 3. Remove the accelerator pedal and sensor assembly from the instrument panel. INSTALLATION 1. Position accelerator pedal and sensor assembly to instrument panel and install lower nut hand tight. 2. Install and tighten accelerator pedal and sensor assembly nuts to 22-28 Nm (17-20 ft lb). 3. Connect the electrical connectors to the IVS and AP sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow Sensor: Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement > Page 2849 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 Full Body View (Part 3 Of 3) The Barometric Pressure Sensor is located behind the LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 2853 Barometric Pressure Sensor: Description and Operation Barometric Pressure Sensor The Barometric Pressure (BARO) sensor is a variable capacitance sensor that, when supplied with a 5-volt reference signal from the Powertrain Control Module (PCM), produces an analog voltage that indicates barometric pressure. The sensor signal is used to determine altitude to adjust timing and quantity of fuel to optimize engine operation. The output of the barometric pressure sensor is one of the variables used to calculate glow plug on time. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 2854 Barometric Pressure Sensor: Service and Repair Barometric Pressure Sensor REMOVAL 1. Disconnect Barometric Pressure (BARO) sensor electrical connector. 2. Remove BARO sensor. INSTALLATION 1. Install BARO sensor. 2. Connect sensor electrical connector Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: Customer Interest Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 2863 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 2869 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2870 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located at the front of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2871 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor is a Hall effect sensor that generates a digital frequency while windows in a target wheel pass through its magnetic field. The frequency of the windows passing by the sensor, as well as the width of selected windows, allows the Powertrain Control Module (PCM) to detect engine speed and position. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 2872 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect Camshaft Position (CMP) sensor electrical connector. 2. Remove bolt and CMP sensor. INSTALLATION 1. Install CMP sensor and bolt. 2. Connect CMP sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation Cylinder Identification Sensor: Description and Operation PURPOSE The Cylinder Identification (CID) circuit output provides information to the Injector Driver Module (IDM) on the position of each cylinder's TDC position. so that current can be applied to the correct injector at the proper time. OPERATION The CID is one of two digital control signals used by the IDM. The CID is produced in the Powertrain Control Module (PCM) and sent to the IDM via the CID circuit. The CID provides synchronization information to the engine's first and fifth injector in the firing order. The IDM then uses this information to properly control injector operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation Engine Oil Temperature (EOT) Sensor: Description and Operation Engine Oil Temperature Sensor The Engine Oil Temperature (EOT) sensor changes resistance in response to changing temperature of the engine oil. The engine oil temperature sensor resistance decreases as the engine oil temperature increases providing a signal to the Powertrain Control Module (PCM), indicating the temperature of the engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation > Page 2879 Engine Oil Temperature (EOT) Sensor: Service and Repair REMOVAL 1. Disconnect engine oil temperature sensor electrical connector. 2. Approximately 0.94 liters (one quart) of engine oil must be removed prior to sensor removal. Remove one quart of engine oil from high pressure oil pump reservoir using Rotunda Vacuum Tester 014-R1058 or equivalent. 3. Remove engine oil temperature sensor. INSTALLATION 1. Install engine oil temperature sensor. 2. Connect engine oil temperature sensor electrical connector. 3. Fill engine oil to proper level. 4. Refill oil pump reservoir with engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Air Temperature Sensor 16-24 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2883 Intake Air Temperature Sensor: Locations Engine Compartment View The Intake Air Temperature Sensor is located at the center of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2884 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor The Intake Air Temperature (IAT) sensor changes resistance in response to changing intake air temperature. The IAT sensor resistance decreases as the air temperature increases, providing a signal to the Powertrain Control Module (PCM) indicating temperature of the incoming intake air. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2885 Intake Air Temperature Sensor: Service and Repair Intake Air Temperature Sensor REMOVAL 1. Disconnect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect wire harness from Intake Air Temperature (IAT) sensor. 3. Remove IAT sensor from air cleaner housing. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten intake air temperature sensor to 16-24 Nm (12-15 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations Manifold Absolute Pressure Sensor: Locations Engine Compartment View The Manifold Absolute Pressure Sensor is located at the right side of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 2889 Manifold Absolute Pressure Sensor: Description and Operation Manifold Absolute Pressure Sensor The Manifold Absolute Pressure (MAP) sensor is used on some applications. The MAP sensor measures the pressure in the intake manifold and provides this information as a variable frequency signal to the Powertrain Control Module (PCM). With the Ignition Switch in the Key ON/Engine OFF position, the MAP sensor will indicate the barometric pressure in the intake manifold. The MAP sensor is used to indicate boost pressure on the diesel engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 2890 Manifold Absolute Pressure Sensor: Service and Repair Manifold Absolute Pressure Sensor REMOVAL 1 Disconnect battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect vacuum hose from Manifold Absolute Pressure (MAP) sensor. 3. Remove fasteners attaching MAP sensor and bracket assembly below cowl drip rail. INSTALLATION Follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2895 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2896 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2897 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2898 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2899 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2900 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2901 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2902 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2903 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2904 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2905 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2906 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2907 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2908 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2909 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Exhaust Back Pressure Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 2914 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations Behind Instrument Panel Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations > Page 2918 Throttle Full Close Switch: Description and Operation The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations > Page 2919 Throttle Full Close Switch: Service and Repair Removal 1. Disconnect the electrical connectors from the idle validation switch and the accelerator pedal position sensor. 2. Remove the nuts holding the accelerator pedal and sensor assembly to the instrument panel. 3. Remove the accelerator pedal and sensor assembly from the instrument panel. Installation 1. Position accelerator pedal and sensor assembly to instrument panel and install accelerator pedal and sensor assembly lower nut hand tight. 2. Install and tighten the accelerator pedal and sensor assembly nuts to 21-29 nm (15-21 lb-ft). 3. Connect the electrical connectors to the idle validation switch and the accelerator pedal position sensor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations > Page 2920 Accelerator Pedal Sensors Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: Customer Interest A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission Transmission Position Switch/Sensor: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission > Page 2936 Transmission Position Switch/Sensor: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only > Page 2939 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission Transmission Position Switch/Sensor: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission > Page 2942 Transmission Position Switch/Sensor: Testing and Inspection With 4R70W Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2947 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2948 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2949 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2950 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2951 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2952 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2953 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2954 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor The Vehicle Speed Sensor (VSS) is mounted on the front of the rear axle housing above the pinion flange. The speed sensor ring is located in the rear axle between the ring gear and differential case. The signal from the sensor is not routed directly to the Powertrain Control Module (PCM). It is received by the Programmable Speedometer/Odometer Module (PSOM), which provides the PCM with a vehicle speed signal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2955 Vehicle Speed Sensor: Testing and Inspection Vehicle Speed Sensor Schematic DESCRIPTION The Vehicle Speed Sensor (VSS) is a variable reluctance sensor that generates a waveform with a frequency that is proportional to vehicle speed. When the vehicle is moving slowly, the sensor produces a low frequency signal. As the vehicle speed increases, the sensor produces a higher frequency signal. The Powertrain Control Module (PCM) uses this signal to control fuel injection, ignition timing and transmission/transaxle shift points. This Pinpoint Test is intended to diagnose only the following: VSS Harness Circuits - Vehicle Speed Sensor - PCM Test DP1 - Continuous Code 29/452: Complete VSS Drive Cycle Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2956 Test DP2,3 and 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Exhaust Back Pressure Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 2962 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Engine Control - Poor Acceleration Response Accelerator Pedal Position Sensor: Technical Service Bulletins Engine Control - Poor Acceleration Response Article No. 03-21-6 10/06/03 DRIVEABILITY - ACCELERATOR PEDAL - LACK OF ACCELERATOR CONTROL WHEN MOVING FROM IDLE POSITION - POOR OR NO ENGINE RESPONSE - 7.3L DIT FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 95-10-10 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A lack of accelerator control when moving off of the idle position may occur on some vehicles. The vehicle's engine will be at idle RPM only. This may be caused by the Idle Validation Switch (IVS) contacts not properly closing due to interference of contacts with the switch housing. ACTION Remove and install a revised accelerator pedal assembly which includes IVS. Refer to the appropriate year 7.3L Turbo Diesel Service Manual Supplement, Pages 10-02-2 and 10-02-3, for service procedures. NOTE THE IVS DATE OF MANUFACTURE IS STAMPED NEAR ITS CONNECTOR MATING SURFACE. THE DATE CODE READS AS FOLLOWS: TWO (2) DIGITS FOR CALENDAR YEAR, FOLLOWED BY TWO (2) DIGITS FOR WEEK OF CALENDAR YEAR WHEN MANUFACTURED. FOR EXAMPLE: 9503 INDICATES SWITCH MADE THE THIRD WEEK OF 1995. NOTE ALL SWITCHES WITH A DATE CODE OF 9510 AND LATER HAVE THE CORRECTED SWITCH HOUSING. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-10-10 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 2968 Accelerator Pedal Position Sensor: Specifications Accelerator Pedal Position Sensor 22-28 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 2969 Accelerator Pedal Position Sensor: Locations Full Body View (Part 3 Of 3) The Accelerator Pedal Position Sensor is located behind LH side of instrument panel, above accelerator pedal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor: Description and Operation Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor The Accelerator Pedal (AP) position sensor is a potentiometer that provides a signal to the Powertrain Control Module (PCM) proportional to the accelerator pedal position. The AP position sensor connects to the accelerator pedal shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor > Page 2972 Accelerator Pedal Position Sensor: Description and Operation Idle Validation Switch The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 2973 Accelerator Pedal Position Sensor: Adjustments The Accelerator Pedal (AP) position sensor cannot be adjusted. If service is required, replace accelerator pedal and shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 2974 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor CAUTION: The accelerator pedal assembly is a calibrated unit and must be handled with care. REMOVAL 1. Disconnect the electrical connectors from the Idle Validation Switch (IVS) and the Accelerator Pedal Position (AP) sensor. 2. remove the bolts holding the accelerator pedal and shaft to the instrument panel, 3. Remove the accelerator pedal and sensor assembly from the instrument panel. INSTALLATION 1. Position accelerator pedal and sensor assembly to instrument panel and install lower nut hand tight. 2. Install and tighten accelerator pedal and sensor assembly nuts to 22-28 Nm (17-20 ft lb). 3. Connect the electrical connectors to the IVS and AP sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow Sensor: Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement > Page 2979 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Filter Restriction Sensor > Component Information > Description and Operation Fuel Filter Restriction Sensor: Description and Operation The 7.3L diesel engine is equipped with a fuel filter restriction sensor. A restriction indicator light is provided on the instrument panel (04320) to alert the operator. If the restriction indicator light goes on during normal operation, the fuel filter should be changed as soon as practical. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Injection Control Pressure Sensor (ICP) <--> [Fuel Pressure Sensor/Switch] > Component Information > Locations Injection Control Pressure Sensor (ICP): Locations Sensor And Actuator Locations The Injection Control Pressure (ICP) is located in the cylinder head oil gallery. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Injection Control Pressure Sensor (ICP) <--> [Fuel Pressure Sensor/Switch] > Component Information > Locations > Page 2986 Injection Control Pressure Sensor (ICP): Description and Operation Injection Control Pressure Sensor The Injection Control Pressure (ICP) sensor is a variable capacitance sensor that, when supplied with a 5-volt reference signal from the Powertrain Control Module (PCM), produces a linear analog voltage signal that indicates oil pressure. The ICP sensor provides a feedback signal to indicate high pressure oil so that the PCM can command the correct injector timing, pulse width and injection control pressure for proper fuel delivery at all speed and load conditions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Injection Control Pressure Sensor (ICP) <--> [Fuel Pressure Sensor/Switch] > Component Information > Locations > Page 2987 Injection Control Pressure Sensor (ICP): Service and Repair Injection Control Pressure Sensor REMOVAL 1. Disconnect Injection Control Pressure (ICP) sensor electrical connector. 2. Remove ICP sensor. INSTALLATION 1. Install ICP sensor. 2. Connect sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations Behind Instrument Panel Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations > Page 2991 Throttle Full Close Switch: Description and Operation The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations > Page 2992 Throttle Full Close Switch: Service and Repair Removal 1. Disconnect the electrical connectors from the idle validation switch and the accelerator pedal position sensor. 2. Remove the nuts holding the accelerator pedal and sensor assembly to the instrument panel. 3. Remove the accelerator pedal and sensor assembly from the instrument panel. Installation 1. Position accelerator pedal and sensor assembly to instrument panel and install accelerator pedal and sensor assembly lower nut hand tight. 2. Install and tighten the accelerator pedal and sensor assembly nuts to 21-29 nm (15-21 lb-ft). 3. Connect the electrical connectors to the idle validation switch and the accelerator pedal position sensor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations > Page 2993 Accelerator Pedal Sensors Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: Customer Interest Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 3003 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 3009 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3010 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located at the front of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3011 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor is a Hall effect sensor that generates a digital frequency while windows in a target wheel pass through its magnetic field. The frequency of the windows passing by the sensor, as well as the width of selected windows, allows the Powertrain Control Module (PCM) to detect engine speed and position. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3012 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect Camshaft Position (CMP) sensor electrical connector. 2. Remove bolt and CMP sensor. INSTALLATION 1. Install CMP sensor and bolt. 2. Connect CMP sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams Ignition Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 3016 Ignition Switch: Testing and Inspection Ignition Switch - Component Testing Procedure (Part 1 Of 2) Ignition Switch - Component Testing Procedure (Part 2 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 3017 Ignition Switch - Terminal Locations Ignition Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Fuel Pressure Regulator The fuel pressure test port is a Schrader valve mounted on the fuel pressure regulator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments Idle Speed: Adjustments Engine idle speed and injection timing are controlled by the Powertrain Control Module (PCM) and are not adjustable. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Tag, disconnect, and position out of the way, any tubes or hoses attached to the air cleaner outlet tube. 2. Loosen clamps as necessary, at both ends of the air cleaner outlet tube. 3. Disconnect and remove air cleaner outlet tube. INSTALLATION Follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation Air Filter Element: Description and Operation AIR INDUCTION SYSTEM Air enters a dry-type engine air cleaner and travels through a pleated, chemically treated, water resistant paper air cleaner element to remove contaminants before entering the engine induction system. The 7.3L Direct Injection (DI) turbo diesel engine also uses a pleated-paper upright type element. Use of other than specific Ford replacement filters may result in significantly shortened filter life and consequent dirt injection. AIR CLEANER ELEMENT Dry-type engine air cleaners are standard on all light truck vehicles. The 7.3L diesel engine also uses a pleated-paper panel type air cleaner element which features an expanding foam filter media attached to the sides of the paper. Use of other than specific Ford replacement air cleaner elements may result in significantly shortened filter life and consequent engine damage. The air cleaner elements should be inspected, and/or replaced periodically according to the maintenance schedule. The air cleaner system has an Intake Air Temperature (IAT) mounted in the outlet hose to monitor engine inlet air temperature. Air Restriction Gauge On diesel engines, replace air cleaner element according to air restriction gauge. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 3033 Air Filter Element: Testing and Inspection Air Restriction Gauge Air Restriction Gauge The 7.3L diesel engine air induction system uses an air restriction indicator to indicate when to change the air cleaner element. The air cleaner element should be replaced when the yellow band in the indicator reaches the CHANGE FILTER mark. Engine performance and fuel economy are adversely affected when maximum restriction is reached. After servicing the air cleaner element, the air restriction indicator can be reset by pushing the button on the end of the indicator. The air restriction indicator is located on the clean-air side of the engine air cleaner. Air Inlet Restriction Check The best method for determining dry-type air cleaner maintenance periods on diesel equipped vehicles is by periodically checking the air restriction indicator. It is recommended that the air restriction indicator be used to determine service intervals. A visual inspection of the air cleaner element will not determine the need for service. Overservicing is not recommended. Air Cleaner Element CAUTION: If the air cleaner element, engine air cleaner or air cleaner outlet tube is removed, use a clean shop rag to prevent contaminants from entering the engine. 1. Replace the air cleaner element according to the maintenance schedule. 2. Check the old air cleaner element. It could help to detect foreign material on the sealing surface that is causing leakage. A streak of dust on the clean air side of the air cleaner element seal is the tell-tale sign. If it exists, be sure the cause is removed before installing a new air cleaner element. 3. Inspect the new air cleaner element for damage. Always look for possible shipping or handling damage. Pay particular attention to the seals. Check for cuts, etc.. Do not use a damaged air cleaner element. 4. Insert the new air cleaner element properly. Cover pressure is not necessary to compress the air cleaner element seal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 3034 Air Filter Element: Service and Repair REMOVAL CAUTION: A special filtering medium is required on Diesel engines. Use only a specific Ford replacement. Use of other Air Cleaner Elements (ACL Element) could result in serious engine damage. Do not attempt to clean ACL Element. Discard and replace. 1. Disconnect and position out of the way any tubes, hoses, or ducts that will interfere with opening the engine Air Cleaner (ACL). CAUTION: Whenever the ACL system is taken apart, use a clean shop rag to prevent contaminants from entering the air intake system. 2. Remove clamps or screws as necessary to remove ACL cover. 3. Remove the ACL cover. 4. Remove the ACL Element, being careful to not loosen any dirt or debris. INSTALLATION 1. Before installing a new ACL Element, check the following items: - Gasket surfaces should be clean and undamaged. - Inlet tube should be clean and undamaged. - ACL Element should be dry and free of holes, ruptures, dents, and damaged gaskets. - Inspect inlet snouts for possible obstructions. 2. Install new ACL Element. 3. Replace upper ACL housing. 4. Attach any tubes, hoses, or ducts as required to upper ACL housing. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information Fuel Pressure Release: Customer Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information > Page 3040 Fuel Pressure Release: Technician Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3041 Fuel Pressure Release: Service and Repair 1. Remove fuel tank filler cap to relieve any pressure in the tank. CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. 2. When servicing the fuel lines, loosen the fuel fitting to allow any residual fuel line pressure to be relieved. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order: 1-2-7-3-4-5-6-8 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression pressures are considered within specification if they are at least 350 psi and the lowest reading cylinder is within 50 psi of the highest. NOTE: Variations exceeding specifications indicate an improperly seated valve or worn/broken piston rings. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3048 Compression Check: Testing and Inspection 1. Warm engine to normal operating temperature, then turn ignition off. 2. Remove the alternator retaining bolt and electrical connectors and and position aside. 3. Remove drive belt. 4. Remove the alternator bracket retaining bolts. 5. Remove the alternator with the bracket attached. 6. Remove the dipstick assembly and bracket. 7. Remove the fuel injector wiring harness connector from the valve cover gasket. 8. Remove valve covers. 9. Unplug harness from the glow plugs and remove all glow plugs. 10. Install suitable compression gauge into cylinder No. 1 glow plug hole. 11. Crank engine at least five compression strokes with ignition switch off. Record highest reading indicated. 12. Repeat compression check on each cylinder. 13. Compression pressures are considered within specification if they are at least 350 psi and the lowest reading cylinder is within 50 psi of the highest. 14. Variations exceeding specifications indicate an improperly seated valve or worn/broken piston rings. 15. Reverse procedure to reassemble after tests. CAUTION: Do not add oil to cylinder as this may cause hydrostatic lock. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations Valve Clearance: Locations Front To Rear Left ....................................................................................................................................................... ........................................................ I-E-I-E-I-E-I-E Right .................................................................................................................................................... ......................................................... E-I-E-I-E-I-E-I Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations > Page 3052 Valve Clearance: Adjustments These engines use hydraulic lifters and there is no provision for adjustment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Engine Control - Poor Acceleration Response Accelerator Pedal Position Sensor: Technical Service Bulletins Engine Control - Poor Acceleration Response Article No. 03-21-6 10/06/03 DRIVEABILITY - ACCELERATOR PEDAL - LACK OF ACCELERATOR CONTROL WHEN MOVING FROM IDLE POSITION - POOR OR NO ENGINE RESPONSE - 7.3L DIT FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 95-10-10 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A lack of accelerator control when moving off of the idle position may occur on some vehicles. The vehicle's engine will be at idle RPM only. This may be caused by the Idle Validation Switch (IVS) contacts not properly closing due to interference of contacts with the switch housing. ACTION Remove and install a revised accelerator pedal assembly which includes IVS. Refer to the appropriate year 7.3L Turbo Diesel Service Manual Supplement, Pages 10-02-2 and 10-02-3, for service procedures. NOTE THE IVS DATE OF MANUFACTURE IS STAMPED NEAR ITS CONNECTOR MATING SURFACE. THE DATE CODE READS AS FOLLOWS: TWO (2) DIGITS FOR CALENDAR YEAR, FOLLOWED BY TWO (2) DIGITS FOR WEEK OF CALENDAR YEAR WHEN MANUFACTURED. FOR EXAMPLE: 9503 INDICATES SWITCH MADE THE THIRD WEEK OF 1995. NOTE ALL SWITCHES WITH A DATE CODE OF 9510 AND LATER HAVE THE CORRECTED SWITCH HOUSING. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-10-10 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 3058 Accelerator Pedal Position Sensor: Specifications Accelerator Pedal Position Sensor 22-28 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 3059 Accelerator Pedal Position Sensor: Locations Full Body View (Part 3 Of 3) The Accelerator Pedal Position Sensor is located behind LH side of instrument panel, above accelerator pedal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor: Description and Operation Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor The Accelerator Pedal (AP) position sensor is a potentiometer that provides a signal to the Powertrain Control Module (PCM) proportional to the accelerator pedal position. The AP position sensor connects to the accelerator pedal shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor > Page 3062 Accelerator Pedal Position Sensor: Description and Operation Idle Validation Switch The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 3063 Accelerator Pedal Position Sensor: Adjustments The Accelerator Pedal (AP) position sensor cannot be adjusted. If service is required, replace accelerator pedal and shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 3064 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor CAUTION: The accelerator pedal assembly is a calibrated unit and must be handled with care. REMOVAL 1. Disconnect the electrical connectors from the Idle Validation Switch (IVS) and the Accelerator Pedal Position (AP) sensor. 2. remove the bolts holding the accelerator pedal and shaft to the instrument panel, 3. Remove the accelerator pedal and sensor assembly from the instrument panel. INSTALLATION 1. Position accelerator pedal and sensor assembly to instrument panel and install lower nut hand tight. 2. Install and tighten accelerator pedal and sensor assembly nuts to 22-28 Nm (17-20 ft lb). 3. Connect the electrical connectors to the IVS and AP sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow Sensor: Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement > Page 3069 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Air Temperature Sensor 16-24 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3073 Intake Air Temperature Sensor: Locations Engine Compartment View The Intake Air Temperature Sensor is located at the center of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3074 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor The Intake Air Temperature (IAT) sensor changes resistance in response to changing intake air temperature. The IAT sensor resistance decreases as the air temperature increases, providing a signal to the Powertrain Control Module (PCM) indicating temperature of the incoming intake air. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3075 Intake Air Temperature Sensor: Service and Repair Intake Air Temperature Sensor REMOVAL 1. Disconnect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect wire harness from Intake Air Temperature (IAT) sensor. 3. Remove IAT sensor from air cleaner housing. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten intake air temperature sensor to 16-24 Nm (12-15 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations Barometric Pressure Sensor: Locations Full Body View (Part 3 Of 3) The Barometric Pressure Sensor is located behind the LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 3079 Barometric Pressure Sensor: Description and Operation Barometric Pressure Sensor The Barometric Pressure (BARO) sensor is a variable capacitance sensor that, when supplied with a 5-volt reference signal from the Powertrain Control Module (PCM), produces an analog voltage that indicates barometric pressure. The sensor signal is used to determine altitude to adjust timing and quantity of fuel to optimize engine operation. The output of the barometric pressure sensor is one of the variables used to calculate glow plug on time. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 3080 Barometric Pressure Sensor: Service and Repair Barometric Pressure Sensor REMOVAL 1. Disconnect Barometric Pressure (BARO) sensor electrical connector. 2. Remove BARO sensor. INSTALLATION 1. Install BARO sensor. 2. Connect sensor electrical connector Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: Customer Interest Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 3089 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 3095 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3096 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located at the front of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3097 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor is a Hall effect sensor that generates a digital frequency while windows in a target wheel pass through its magnetic field. The frequency of the windows passing by the sensor, as well as the width of selected windows, allows the Powertrain Control Module (PCM) to detect engine speed and position. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3098 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect Camshaft Position (CMP) sensor electrical connector. 2. Remove bolt and CMP sensor. INSTALLATION 1. Install CMP sensor and bolt. 2. Connect CMP sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation Cylinder Identification Sensor: Description and Operation PURPOSE The Cylinder Identification (CID) circuit output provides information to the Injector Driver Module (IDM) on the position of each cylinder's TDC position. so that current can be applied to the correct injector at the proper time. OPERATION The CID is one of two digital control signals used by the IDM. The CID is produced in the Powertrain Control Module (PCM) and sent to the IDM via the CID circuit. The CID provides synchronization information to the engine's first and fifth injector in the firing order. The IDM then uses this information to properly control injector operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Full Body View (Part 3 Of 3) The Data Link Connector is located below the LH side of instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3107 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3108 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3109 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3110 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3111 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3112 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3113 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3114 Data Link Connector Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Direct Injection System (diesel) > Injector Driver Module > Component Information > Specifications Injector Driver Module: Specifications Injector Driver Module Retaining Bolt 3-4 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Direct Injection System (diesel) > Injector Driver Module > Component Information > Specifications > Page 3119 Injector Driver Module: Locations Engine Compartment View The Injector Driver Module is located at the LH rear of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Direct Injection System (diesel) > Injector Driver Module > Component Information > Specifications > Page 3120 Injector Driver Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Direct Injection System (diesel) > Injector Driver Module > Component Information > Specifications > Page 3121 Injector Driver Module: Service Precautions WARNING: RED-STRIPED WIRES CARRY 115V DC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Direct Injection System (diesel) > Injector Driver Module > Component Information > Specifications > Page 3122 Injector Driver Module: Description and Operation The Injector Driver Module (IDM) supplies 115V DC to all of the fuel injectors. The IDM receives signals from the Powertrain Control Module (PCM) for Cylinder Identification (CID) and Fuel Delivery Command Signal (FDCS). The PCM controls when the timing of the injectors should start and how long the injector is open. The IDM controls the injector firing sequence through output drivers. The IDM has an output driver for each injector: one low side driver for each injector and one high side driver for each bank of injectors. The injector is fired when the output driver closes the circuit to ground, completing the circuit ground path. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Direct Injection System (diesel) > Injector Driver Module > Component Information > Specifications > Page 3123 Injector Driver Module: Service and Repair REMOVAL WARNING: RED-STRIPED WIRES CARRY 115V DC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. 1. Disconnect battery negative cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Remove module bolts. 3. Loosen wiring connector retainer bolt. 4. Remove Injector Driver Module (IDM). INSTALLATION 1. To install, reverse removal procedures. 2. Tighten IDM retainer bolt to 3-4 Nm (27-35 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Direct Injection System (diesel) > Injector Driver Module Relay > Component Information > Description and Operation Injector Driver Module Relay: Description and Operation PURPOSE The Injector Driver Module (IDM) Relay provides power to the IDM. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-24 > Oct > 03 > Engine Control - Cold Temperature Hard Start/No Start Powertrain Control Module: Customer Interest Engine Control - Cold Temperature Hard Start/No Start Article No. 03-21-24 10/06/03 HARD START/NO START - EXTREME COLD AMBIENT TEMPERATURE - VEHICLES WITH 7.3L DIESEL ENGINE FORD: 1992-1996 ECONOLINE Article 97-7-7 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A hard start or no start condition in extreme cold weather may occur on some vehicles. This may be caused by fuel freezing in the delivery module draw tube. ACTION Replace Diesel Delivery Module (DDM) with a revised DDM (-9275-). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. NOTE WHEN REPLACING THE DDM, BE SURE TO CLEAN AREA AROUND FLANGE/TANK OPENING TO PREVENT PARTICULATE MATTER FROM FALLING INTO THE FUEL TANK. 2. Replace the DDM with the revised DDM (-9275-) by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. 3. Reinstall the fuel tank. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-7 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 03-21-24 > Oct > 03 > Engine Control - Cold Temperature Hard Start/No Start Powertrain Control Module: All Technical Service Bulletins Engine Control - Cold Temperature Hard Start/No Start Article No. 03-21-24 10/06/03 HARD START/NO START - EXTREME COLD AMBIENT TEMPERATURE - VEHICLES WITH 7.3L DIESEL ENGINE FORD: 1992-1996 ECONOLINE Article 97-7-7 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A hard start or no start condition in extreme cold weather may occur on some vehicles. This may be caused by fuel freezing in the delivery module draw tube. ACTION Replace Diesel Delivery Module (DDM) with a revised DDM (-9275-). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. NOTE WHEN REPLACING THE DDM, BE SURE TO CLEAN AREA AROUND FLANGE/TANK OPENING TO PREVENT PARTICULATE MATTER FROM FALLING INTO THE FUEL TANK. 2. Replace the DDM with the revised DDM (-9275-) by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. 3. Reinstall the fuel tank. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-7 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 3144 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips > Page 3149 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 3155 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips > Page 3160 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3161 Powertrain Control Module: Specifications PCM Retainer Nuts 3-4 Nm Wiring Connector Retaining Bolts 4 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3162 Powertrain Control Module: Locations Engine Compartment View The Powertrain Control Module is located at the left rear of the engine compartment, near brake master cylinder. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3165 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3166 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3167 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3168 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3169 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3170 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3171 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3172 Powertrain Control Module: Connector Views Powertrain Control Module (Part 1 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3173 Powertrain Control Module (Part 2 Of 2) PCM Pinout Chart PCM Pinout Chart Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3174 PCM Pinout (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3175 Part 2 Of 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3176 Part 3 Of 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3177 Part 4 Of 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3178 Powertrain Control Module: Description and Operation Powertrain Control Module (PCM) The Powertrain Control Module (PCM) retrieves inputs from various engine sensors to compute the required fuel flow rate necessary to maintain a proper air/fuel ratio throughout the entire engine operational range. The PCM also determines and compensates the vehicle's uniqueness. The system will also compensate for changes in altitude (i.e., from sea level to mountains). The 104-pin EEC-V system PCM outputs a command to the Injector Driver Module (IDM) which in turn energizes the fuel injector with up to 115V DC. The fuel injector is controlled by the in IDM to meter the appropriate quantity of fuel at the correct time and duration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3179 Powertrain Control Module: Service and Repair Powertrain Control Module REMOVAL 1. Disconnect battery negative cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Loosen engine control sensor wiring to PCM connector retainer bolt. 3. Remove engine control sensor wiring connector from PCM. 4. Remove the two PCM seal nuts and loosen left fender liner screws and remove liner or bend down to clear powertrain control module. Remove PCM. INSTALLATION 1. Follow removal procedures in reverse order. 2. Tighten PCM retainer screw to 3-4 Nm (27-35 in lb). Tighten engine control sensor wiring connector retainer bolt to 4 Nm (35 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation Engine Oil Temperature (EOT) Sensor: Description and Operation Engine Oil Temperature Sensor The Engine Oil Temperature (EOT) sensor changes resistance in response to changing temperature of the engine oil. The engine oil temperature sensor resistance decreases as the engine oil temperature increases providing a signal to the Powertrain Control Module (PCM), indicating the temperature of the engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation > Page 3183 Engine Oil Temperature (EOT) Sensor: Service and Repair REMOVAL 1. Disconnect engine oil temperature sensor electrical connector. 2. Approximately 0.94 liters (one quart) of engine oil must be removed prior to sensor removal. Remove one quart of engine oil from high pressure oil pump reservoir using Rotunda Vacuum Tester 014-R1058 or equivalent. 3. Remove engine oil temperature sensor. INSTALLATION 1. Install engine oil temperature sensor. 2. Connect engine oil temperature sensor electrical connector. 3. Fill engine oil to proper level. 4. Refill oil pump reservoir with engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations Manifold Absolute Pressure Sensor: Locations Engine Compartment View The Manifold Absolute Pressure Sensor is located at the right side of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 3187 Manifold Absolute Pressure Sensor: Description and Operation Manifold Absolute Pressure Sensor The Manifold Absolute Pressure (MAP) sensor is used on some applications. The MAP sensor measures the pressure in the intake manifold and provides this information as a variable frequency signal to the Powertrain Control Module (PCM). With the Ignition Switch in the Key ON/Engine OFF position, the MAP sensor will indicate the barometric pressure in the intake manifold. The MAP sensor is used to indicate boost pressure on the diesel engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 3188 Manifold Absolute Pressure Sensor: Service and Repair Manifold Absolute Pressure Sensor REMOVAL 1 Disconnect battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect vacuum hose from Manifold Absolute Pressure (MAP) sensor. 3. Remove fasteners attaching MAP sensor and bracket assembly below cowl drip rail. INSTALLATION Follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3193 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3194 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3195 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3196 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3197 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3198 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3199 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3200 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3201 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3202 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3203 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3204 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3205 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3206 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3207 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Exhaust Back Pressure Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 3212 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-24 > Oct > 03 > Engine Control - Cold Temperature Hard Start/No Start Powertrain Control Module: Customer Interest Engine Control - Cold Temperature Hard Start/No Start Article No. 03-21-24 10/06/03 HARD START/NO START - EXTREME COLD AMBIENT TEMPERATURE - VEHICLES WITH 7.3L DIESEL ENGINE FORD: 1992-1996 ECONOLINE Article 97-7-7 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A hard start or no start condition in extreme cold weather may occur on some vehicles. This may be caused by fuel freezing in the delivery module draw tube. ACTION Replace Diesel Delivery Module (DDM) with a revised DDM (-9275-). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. NOTE WHEN REPLACING THE DDM, BE SURE TO CLEAN AREA AROUND FLANGE/TANK OPENING TO PREVENT PARTICULATE MATTER FROM FALLING INTO THE FUEL TANK. 2. Replace the DDM with the revised DDM (-9275-) by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. 3. Reinstall the fuel tank. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-7 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-21-24 > Oct > 03 > Engine Control - Cold Temperature Hard Start/No Start Powertrain Control Module: All Technical Service Bulletins Engine Control - Cold Temperature Hard Start/No Start Article No. 03-21-24 10/06/03 HARD START/NO START - EXTREME COLD AMBIENT TEMPERATURE - VEHICLES WITH 7.3L DIESEL ENGINE FORD: 1992-1996 ECONOLINE Article 97-7-7 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A hard start or no start condition in extreme cold weather may occur on some vehicles. This may be caused by fuel freezing in the delivery module draw tube. ACTION Replace Diesel Delivery Module (DDM) with a revised DDM (-9275-). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the fuel tank by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. NOTE WHEN REPLACING THE DDM, BE SURE TO CLEAN AREA AROUND FLANGE/TANK OPENING TO PREVENT PARTICULATE MATTER FROM FALLING INTO THE FUEL TANK. 2. Replace the DDM with the revised DDM (-9275-) by referring to the appropriate year Econoline Diesel Service Manual Supplement, Section 10-01B. 3. Reinstall the fuel tank. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-7-7 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 3231 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips Powertrain Control Module: All Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips > Page 3236 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: All Technical Service Bulletins Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3247 Powertrain Control Module: Specifications PCM Retainer Nuts 3-4 Nm Wiring Connector Retaining Bolts 4 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3248 Powertrain Control Module: Locations Engine Compartment View The Powertrain Control Module is located at the left rear of the engine compartment, near brake master cylinder. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3251 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3252 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3253 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3254 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3255 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3256 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3257 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3258 Powertrain Control Module: Connector Views Powertrain Control Module (Part 1 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3259 Powertrain Control Module (Part 2 Of 2) PCM Pinout Chart PCM Pinout Chart Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3260 PCM Pinout (Part 1 Of 4) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3261 Part 2 Of 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3262 Part 3 Of 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3263 Part 4 Of 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3264 Powertrain Control Module: Description and Operation Powertrain Control Module (PCM) The Powertrain Control Module (PCM) retrieves inputs from various engine sensors to compute the required fuel flow rate necessary to maintain a proper air/fuel ratio throughout the entire engine operational range. The PCM also determines and compensates the vehicle's uniqueness. The system will also compensate for changes in altitude (i.e., from sea level to mountains). The 104-pin EEC-V system PCM outputs a command to the Injector Driver Module (IDM) which in turn energizes the fuel injector with up to 115V DC. The fuel injector is controlled by the in IDM to meter the appropriate quantity of fuel at the correct time and duration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3265 Powertrain Control Module: Service and Repair Powertrain Control Module REMOVAL 1. Disconnect battery negative cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Loosen engine control sensor wiring to PCM connector retainer bolt. 3. Remove engine control sensor wiring connector from PCM. 4. Remove the two PCM seal nuts and loosen left fender liner screws and remove liner or bend down to clear powertrain control module. Remove PCM. INSTALLATION 1. Follow removal procedures in reverse order. 2. Tighten PCM retainer screw to 3-4 Nm (27-35 in lb). Tighten engine control sensor wiring connector retainer bolt to 4 Nm (35 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Injector Driver Module > Component Information > Specifications Injector Driver Module: Specifications Injector Driver Module Retaining Bolt 3-4 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 3269 Injector Driver Module: Locations Engine Compartment View The Injector Driver Module is located at the LH rear of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 3270 Injector Driver Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 3271 Injector Driver Module: Service Precautions WARNING: RED-STRIPED WIRES CARRY 115V DC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 3272 Injector Driver Module: Description and Operation The Injector Driver Module (IDM) supplies 115V DC to all of the fuel injectors. The IDM receives signals from the Powertrain Control Module (PCM) for Cylinder Identification (CID) and Fuel Delivery Command Signal (FDCS). The PCM controls when the timing of the injectors should start and how long the injector is open. The IDM controls the injector firing sequence through output drivers. The IDM has an output driver for each injector: one low side driver for each injector and one high side driver for each bank of injectors. The injector is fired when the output driver closes the circuit to ground, completing the circuit ground path. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Injector Driver Module > Component Information > Specifications > Page 3273 Injector Driver Module: Service and Repair REMOVAL WARNING: RED-STRIPED WIRES CARRY 115V DC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. 1. Disconnect battery negative cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Remove module bolts. 3. Loosen wiring connector retainer bolt. 4. Remove Injector Driver Module (IDM). INSTALLATION 1. To install, reverse removal procedures. 2. Tighten IDM retainer bolt to 3-4 Nm (27-35 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Injector Driver Module Relay > Component Information > Description and Operation Injector Driver Module Relay: Description and Operation PURPOSE The Injector Driver Module (IDM) Relay provides power to the IDM. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Engine Control - Poor Acceleration Response Accelerator Pedal Position Sensor: Technical Service Bulletins Engine Control - Poor Acceleration Response Article No. 03-21-6 10/06/03 DRIVEABILITY - ACCELERATOR PEDAL - LACK OF ACCELERATOR CONTROL WHEN MOVING FROM IDLE POSITION - POOR OR NO ENGINE RESPONSE - 7.3L DIT FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 95-10-10 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A lack of accelerator control when moving off of the idle position may occur on some vehicles. The vehicle's engine will be at idle RPM only. This may be caused by the Idle Validation Switch (IVS) contacts not properly closing due to interference of contacts with the switch housing. ACTION Remove and install a revised accelerator pedal assembly which includes IVS. Refer to the appropriate year 7.3L Turbo Diesel Service Manual Supplement, Pages 10-02-2 and 10-02-3, for service procedures. NOTE THE IVS DATE OF MANUFACTURE IS STAMPED NEAR ITS CONNECTOR MATING SURFACE. THE DATE CODE READS AS FOLLOWS: TWO (2) DIGITS FOR CALENDAR YEAR, FOLLOWED BY TWO (2) DIGITS FOR WEEK OF CALENDAR YEAR WHEN MANUFACTURED. FOR EXAMPLE: 9503 INDICATES SWITCH MADE THE THIRD WEEK OF 1995. NOTE ALL SWITCHES WITH A DATE CODE OF 9510 AND LATER HAVE THE CORRECTED SWITCH HOUSING. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-10-10 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 3282 Accelerator Pedal Position Sensor: Specifications Accelerator Pedal Position Sensor 22-28 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 3283 Accelerator Pedal Position Sensor: Locations Full Body View (Part 3 Of 3) The Accelerator Pedal Position Sensor is located behind LH side of instrument panel, above accelerator pedal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor: Description and Operation Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor The Accelerator Pedal (AP) position sensor is a potentiometer that provides a signal to the Powertrain Control Module (PCM) proportional to the accelerator pedal position. The AP position sensor connects to the accelerator pedal shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor > Page 3286 Accelerator Pedal Position Sensor: Description and Operation Idle Validation Switch The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 3287 Accelerator Pedal Position Sensor: Adjustments The Accelerator Pedal (AP) position sensor cannot be adjusted. If service is required, replace accelerator pedal and shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 3288 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor CAUTION: The accelerator pedal assembly is a calibrated unit and must be handled with care. REMOVAL 1. Disconnect the electrical connectors from the Idle Validation Switch (IVS) and the Accelerator Pedal Position (AP) sensor. 2. remove the bolts holding the accelerator pedal and shaft to the instrument panel, 3. Remove the accelerator pedal and sensor assembly from the instrument panel. INSTALLATION 1. Position accelerator pedal and sensor assembly to instrument panel and install lower nut hand tight. 2. Install and tighten accelerator pedal and sensor assembly nuts to 22-28 Nm (17-20 ft lb). 3. Connect the electrical connectors to the IVS and AP sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow Sensor: Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement > Page 3293 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 Full Body View (Part 3 Of 3) The Barometric Pressure Sensor is located behind the LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 3297 Barometric Pressure Sensor: Description and Operation Barometric Pressure Sensor The Barometric Pressure (BARO) sensor is a variable capacitance sensor that, when supplied with a 5-volt reference signal from the Powertrain Control Module (PCM), produces an analog voltage that indicates barometric pressure. The sensor signal is used to determine altitude to adjust timing and quantity of fuel to optimize engine operation. The output of the barometric pressure sensor is one of the variables used to calculate glow plug on time. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations > Page 3298 Barometric Pressure Sensor: Service and Repair Barometric Pressure Sensor REMOVAL 1. Disconnect Barometric Pressure (BARO) sensor electrical connector. 2. Remove BARO sensor. INSTALLATION 1. Install BARO sensor. 2. Connect sensor electrical connector Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: Customer Interest Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 3307 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 3313 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3314 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located at the front of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3315 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor is a Hall effect sensor that generates a digital frequency while windows in a target wheel pass through its magnetic field. The frequency of the windows passing by the sensor, as well as the width of selected windows, allows the Powertrain Control Module (PCM) to detect engine speed and position. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3316 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect Camshaft Position (CMP) sensor electrical connector. 2. Remove bolt and CMP sensor. INSTALLATION 1. Install CMP sensor and bolt. 2. Connect CMP sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation Cylinder Identification Sensor: Description and Operation PURPOSE The Cylinder Identification (CID) circuit output provides information to the Injector Driver Module (IDM) on the position of each cylinder's TDC position. so that current can be applied to the correct injector at the proper time. OPERATION The CID is one of two digital control signals used by the IDM. The CID is produced in the Powertrain Control Module (PCM) and sent to the IDM via the CID circuit. The CID provides synchronization information to the engine's first and fifth injector in the firing order. The IDM then uses this information to properly control injector operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation Engine Oil Temperature (EOT) Sensor: Description and Operation Engine Oil Temperature Sensor The Engine Oil Temperature (EOT) sensor changes resistance in response to changing temperature of the engine oil. The engine oil temperature sensor resistance decreases as the engine oil temperature increases providing a signal to the Powertrain Control Module (PCM), indicating the temperature of the engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Oil Temperature (EOT) Sensor <--> [Engine Temperature Sensor] > Component Information > Description and Operation > Page 3323 Engine Oil Temperature (EOT) Sensor: Service and Repair REMOVAL 1. Disconnect engine oil temperature sensor electrical connector. 2. Approximately 0.94 liters (one quart) of engine oil must be removed prior to sensor removal. Remove one quart of engine oil from high pressure oil pump reservoir using Rotunda Vacuum Tester 014-R1058 or equivalent. 3. Remove engine oil temperature sensor. INSTALLATION 1. Install engine oil temperature sensor. 2. Connect engine oil temperature sensor electrical connector. 3. Fill engine oil to proper level. 4. Refill oil pump reservoir with engine oil. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Intake Air Temperature Sensor 16-24 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3327 Intake Air Temperature Sensor: Locations Engine Compartment View The Intake Air Temperature Sensor is located at the center of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3328 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor The Intake Air Temperature (IAT) sensor changes resistance in response to changing intake air temperature. The IAT sensor resistance decreases as the air temperature increases, providing a signal to the Powertrain Control Module (PCM) indicating temperature of the incoming intake air. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3329 Intake Air Temperature Sensor: Service and Repair Intake Air Temperature Sensor REMOVAL 1. Disconnect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect wire harness from Intake Air Temperature (IAT) sensor. 3. Remove IAT sensor from air cleaner housing. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten intake air temperature sensor to 16-24 Nm (12-15 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations Manifold Absolute Pressure Sensor: Locations Engine Compartment View The Manifold Absolute Pressure Sensor is located at the right side of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 3333 Manifold Absolute Pressure Sensor: Description and Operation Manifold Absolute Pressure Sensor The Manifold Absolute Pressure (MAP) sensor is used on some applications. The MAP sensor measures the pressure in the intake manifold and provides this information as a variable frequency signal to the Powertrain Control Module (PCM). With the Ignition Switch in the Key ON/Engine OFF position, the MAP sensor will indicate the barometric pressure in the intake manifold. The MAP sensor is used to indicate boost pressure on the diesel engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Locations > Page 3334 Manifold Absolute Pressure Sensor: Service and Repair Manifold Absolute Pressure Sensor REMOVAL 1 Disconnect battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect vacuum hose from Manifold Absolute Pressure (MAP) sensor. 3. Remove fasteners attaching MAP sensor and bracket assembly below cowl drip rail. INSTALLATION Follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3339 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3340 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3341 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3342 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3343 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3344 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3345 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3346 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3347 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3348 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3349 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3350 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3351 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3352 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3353 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Exhaust Back Pressure Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 3358 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations Behind Instrument Panel Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations > Page 3362 Throttle Full Close Switch: Description and Operation The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations > Page 3363 Throttle Full Close Switch: Service and Repair Removal 1. Disconnect the electrical connectors from the idle validation switch and the accelerator pedal position sensor. 2. Remove the nuts holding the accelerator pedal and sensor assembly to the instrument panel. 3. Remove the accelerator pedal and sensor assembly from the instrument panel. Installation 1. Position accelerator pedal and sensor assembly to instrument panel and install accelerator pedal and sensor assembly lower nut hand tight. 2. Install and tighten the accelerator pedal and sensor assembly nuts to 21-29 nm (15-21 lb-ft). 3. Connect the electrical connectors to the idle validation switch and the accelerator pedal position sensor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations > Page 3364 Accelerator Pedal Sensors Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: Customer Interest A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission Transmission Position Switch/Sensor: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission > Page 3380 Transmission Position Switch/Sensor: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only > Page 3383 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission Transmission Position Switch/Sensor: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission > Page 3386 Transmission Position Switch/Sensor: Testing and Inspection With 4R70W Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3396 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3397 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3398 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor The Vehicle Speed Sensor (VSS) is mounted on the front of the rear axle housing above the pinion flange. The speed sensor ring is located in the rear axle between the ring gear and differential case. The signal from the sensor is not routed directly to the Powertrain Control Module (PCM). It is received by the Programmable Speedometer/Odometer Module (PSOM), which provides the PCM with a vehicle speed signal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3399 Vehicle Speed Sensor: Testing and Inspection Vehicle Speed Sensor Schematic DESCRIPTION The Vehicle Speed Sensor (VSS) is a variable reluctance sensor that generates a waveform with a frequency that is proportional to vehicle speed. When the vehicle is moving slowly, the sensor produces a low frequency signal. As the vehicle speed increases, the sensor produces a higher frequency signal. The Powertrain Control Module (PCM) uses this signal to control fuel injection, ignition timing and transmission/transaxle shift points. This Pinpoint Test is intended to diagnose only the following: VSS Harness Circuits - Vehicle Speed Sensor - PCM Test DP1 - Continuous Code 29/452: Complete VSS Drive Cycle Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3400 Test DP2,3 and 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations Behind Instrument Panel Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations > Page 3404 Throttle Full Close Switch: Description and Operation The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations > Page 3405 Throttle Full Close Switch: Service and Repair Removal 1. Disconnect the electrical connectors from the idle validation switch and the accelerator pedal position sensor. 2. Remove the nuts holding the accelerator pedal and sensor assembly to the instrument panel. 3. Remove the accelerator pedal and sensor assembly from the instrument panel. Installation 1. Position accelerator pedal and sensor assembly to instrument panel and install accelerator pedal and sensor assembly lower nut hand tight. 2. Install and tighten the accelerator pedal and sensor assembly nuts to 21-29 nm (15-21 lb-ft). 3. Connect the electrical connectors to the idle validation switch and the accelerator pedal position sensor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Close Switch > Component Information > Locations > Page 3406 Accelerator Pedal Sensors Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: Customer Interest A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission Transmission Position Switch/Sensor: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission > Page 3422 Transmission Position Switch/Sensor: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only > Page 3425 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission Transmission Position Switch/Sensor: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission > Page 3428 Transmission Position Switch/Sensor: Testing and Inspection With 4R70W Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3433 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3434 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3435 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3436 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3437 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3438 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3439 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3440 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor The Vehicle Speed Sensor (VSS) is mounted on the front of the rear axle housing above the pinion flange. The speed sensor ring is located in the rear axle between the ring gear and differential case. The signal from the sensor is not routed directly to the Powertrain Control Module (PCM). It is received by the Programmable Speedometer/Odometer Module (PSOM), which provides the PCM with a vehicle speed signal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3441 Vehicle Speed Sensor: Testing and Inspection Vehicle Speed Sensor Schematic DESCRIPTION The Vehicle Speed Sensor (VSS) is a variable reluctance sensor that generates a waveform with a frequency that is proportional to vehicle speed. When the vehicle is moving slowly, the sensor produces a low frequency signal. As the vehicle speed increases, the sensor produces a higher frequency signal. The Powertrain Control Module (PCM) uses this signal to control fuel injection, ignition timing and transmission/transaxle shift points. This Pinpoint Test is intended to diagnose only the following: VSS Harness Circuits - Vehicle Speed Sensor - PCM Test DP1 - Continuous Code 29/452: Complete VSS Drive Cycle Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3442 Test DP2,3 and 4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > AIRB Solenoid <--> [Air Injection Bypass Valve] > Component Information > Technical Service Bulletins > Customer Interest for AIRB Solenoid: > 9599 > May > 95 > Thermactor System - Buzzing Noise AIRB Solenoid: Customer Interest Thermactor System - Buzzing Noise Article No. 95-9-9 05/08/95 ^ THERMACTOR SYSTEM - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY ^ NOISE - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - THERMACTOR SYSTEM OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY LIGHT TRUCK: 1994-95 E-350 ISSUE: A "buzzing" noise may be heard between 25-40 mph while in 2nd or 3rd gear. This may be caused by air flow through the thermactor system during operation in dump mode. ACTION: Replace the air supply bypass valve hose with a cap on the intake air duct and install a thermactor silencer and bracket assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the air dump hose which connects the thermactor bypass valve to the fresh air intake air duct. 2. Cap the open nipple on the intake air duct with a Rubber Cap (C6AZ-9486-A). No clamps are necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > AIRB Solenoid <--> [Air Injection Bypass Valve] > Component Information > Technical Service Bulletins > Customer Interest for AIRB Solenoid: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 3453 3. Install one (1) end of the Air Supply Pump Silencer Hose (F4TZ-9H458-A) onto the Silencer and Bracket Assembly (F4TZ-9H467-B) and secure with a Crimp Clamp (F1HZ-9H447-AA). Refer to Figure 1. 4. Remove the bolt from the engine installed thermactor assembly and install silencer and hose assembly. Refer to Figure 1. 5. Reinstall the bolt and torque to 11-19 N-m (8-14 lb.ft.). No clamp is necessary at the end of the hose. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > AIRB Solenoid <--> [Air Injection Bypass Valve] > Component Information > Technical Service Bulletins > Customer Interest for AIRB Solenoid: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 3454 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950909A Replace Air Dump Hose 0.4 Hr. With Cap And Install Silencer Assembly DEALER CODING CONDITION BASIC PART NO. CODE 9F870 56 OASIS CODES: 403000, 702000, 702300, 703000, 703300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > AIRB Solenoid <--> [Air Injection Bypass Valve] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for AIRB Solenoid: > 9599 > May > 95 > Thermactor System - Buzzing Noise AIRB Solenoid: All Technical Service Bulletins Thermactor System - Buzzing Noise Article No. 95-9-9 05/08/95 ^ THERMACTOR SYSTEM - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY ^ NOISE - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - THERMACTOR SYSTEM OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY LIGHT TRUCK: 1994-95 E-350 ISSUE: A "buzzing" noise may be heard between 25-40 mph while in 2nd or 3rd gear. This may be caused by air flow through the thermactor system during operation in dump mode. ACTION: Replace the air supply bypass valve hose with a cap on the intake air duct and install a thermactor silencer and bracket assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the air dump hose which connects the thermactor bypass valve to the fresh air intake air duct. 2. Cap the open nipple on the intake air duct with a Rubber Cap (C6AZ-9486-A). No clamps are necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > AIRB Solenoid <--> [Air Injection Bypass Valve] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for AIRB Solenoid: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 3460 3. Install one (1) end of the Air Supply Pump Silencer Hose (F4TZ-9H458-A) onto the Silencer and Bracket Assembly (F4TZ-9H467-B) and secure with a Crimp Clamp (F1HZ-9H447-AA). Refer to Figure 1. 4. Remove the bolt from the engine installed thermactor assembly and install silencer and hose assembly. Refer to Figure 1. 5. Reinstall the bolt and torque to 11-19 N-m (8-14 lb.ft.). No clamp is necessary at the end of the hose. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > AIRB Solenoid <--> [Air Injection Bypass Valve] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for AIRB Solenoid: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 3461 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950909A Replace Air Dump Hose 0.4 Hr. With Cap And Install Silencer Assembly DEALER CODING CONDITION BASIC PART NO. CODE 9F870 56 OASIS CODES: 403000, 702000, 702300, 703000, 703300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Muffler > Component Information > Technical Service Bulletins > Customer Interest for Air Injection Muffler: > 9599 > May > 95 > Thermactor System - Buzzing Noise Air Injection Muffler: Customer Interest Thermactor System - Buzzing Noise Article No. 95-9-9 05/08/95 ^ THERMACTOR SYSTEM - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY ^ NOISE - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - THERMACTOR SYSTEM OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY LIGHT TRUCK: 1994-95 E-350 ISSUE: A "buzzing" noise may be heard between 25-40 mph while in 2nd or 3rd gear. This may be caused by air flow through the thermactor system during operation in dump mode. ACTION: Replace the air supply bypass valve hose with a cap on the intake air duct and install a thermactor silencer and bracket assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the air dump hose which connects the thermactor bypass valve to the fresh air intake air duct. 2. Cap the open nipple on the intake air duct with a Rubber Cap (C6AZ-9486-A). No clamps are necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Muffler > Component Information > Technical Service Bulletins > Customer Interest for Air Injection Muffler: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 3470 3. Install one (1) end of the Air Supply Pump Silencer Hose (F4TZ-9H458-A) onto the Silencer and Bracket Assembly (F4TZ-9H467-B) and secure with a Crimp Clamp (F1HZ-9H447-AA). Refer to Figure 1. 4. Remove the bolt from the engine installed thermactor assembly and install silencer and hose assembly. Refer to Figure 1. 5. Reinstall the bolt and torque to 11-19 N-m (8-14 lb.ft.). No clamp is necessary at the end of the hose. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Muffler > Component Information > Technical Service Bulletins > Customer Interest for Air Injection Muffler: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 3471 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950909A Replace Air Dump Hose 0.4 Hr. With Cap And Install Silencer Assembly DEALER CODING CONDITION BASIC PART NO. CODE 9F870 56 OASIS CODES: 403000, 702000, 702300, 703000, 703300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Injection Muffler: > 9599 > May > 95 > Thermactor System - Buzzing Noise Air Injection Muffler: All Technical Service Bulletins Thermactor System - Buzzing Noise Article No. 95-9-9 05/08/95 ^ THERMACTOR SYSTEM - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY ^ NOISE - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - THERMACTOR SYSTEM OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY LIGHT TRUCK: 1994-95 E-350 ISSUE: A "buzzing" noise may be heard between 25-40 mph while in 2nd or 3rd gear. This may be caused by air flow through the thermactor system during operation in dump mode. ACTION: Replace the air supply bypass valve hose with a cap on the intake air duct and install a thermactor silencer and bracket assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the air dump hose which connects the thermactor bypass valve to the fresh air intake air duct. 2. Cap the open nipple on the intake air duct with a Rubber Cap (C6AZ-9486-A). No clamps are necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Injection Muffler: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 3477 3. Install one (1) end of the Air Supply Pump Silencer Hose (F4TZ-9H458-A) onto the Silencer and Bracket Assembly (F4TZ-9H467-B) and secure with a Crimp Clamp (F1HZ-9H447-AA). Refer to Figure 1. 4. Remove the bolt from the engine installed thermactor assembly and install silencer and hose assembly. Refer to Figure 1. 5. Reinstall the bolt and torque to 11-19 N-m (8-14 lb.ft.). No clamp is necessary at the end of the hose. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Injection Muffler: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 3478 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950909A Replace Air Dump Hose 0.4 Hr. With Cap And Install Silencer Assembly DEALER CODING CONDITION BASIC PART NO. CODE 9F870 56 OASIS CODES: 403000, 702000, 702300, 703000, 703300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise Catalyst Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 3488 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 3489 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3495 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3496 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalyst Shield: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake ON/OFF Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Catalyst Shield: > NHTSA 06V286000 > Jul > 06 > Recall 06V286000: Cruise Control Switch Fire Hazard Brake ON/OFF Switch: All Technical Service Bulletins Recall 06V286000: Cruise Control Switch Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/E450 1996-2002 Ford/Econoline 1994-1996 Ford/Excursion 2000-2002 Ford/Explorer 1998 Ford/F250 1994-2002 Ford/F350 1994-2002 Ford/F450 1994-2002 Ford/F550 1994-2002 Ford/Mountaineer 1998 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 06V286000 MFG'S REPORT DATE: July 27, 2006 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 1200000 SUMMARY: On certain trucks equipped with speed control, gasoline or natural gas engines, the speed control deactivation switch may overheat. CONSEQUENCE: Overheat could result in smoke, or burn and in an underhood fire. REMEDY: Dealers will install a fused wiring harness into the speed control system free of charge. The recall is expected to begin on August 7, 2006. Owners may contact Ford at 1-866-436-7332. NOTES: Ford recall No. 05S28. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Exhaust Back Pressure Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 3520 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation Positive Crankcase Ventilation: Description and Operation DESCRIPTION AND OPERATION The engine is equipped with a fully closed-crankcase ventilation system. Crankcase vapors are directed into the combustion chamber from the crankcase breather assembly located on the left valve cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 3524 Positive Crankcase Ventilation: Service and Repair REMOVAL 1. Remove the intake duct tube assembly bolts and the clamps at turbocharger and air cleaner. Remove the air inlet duct tube assembly. 2. Remove the two crankcase breather hose clamps and crankcase breather screws. INSTALLATION 1. Install the two crankcase breather screws, crankcase breather hose, and clamps. 2. Install the air inlet duct tube assembly and the clamps at the turbocharger and air cleaner. 3. Install the intake duct tube assembly bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Exhaust Back Pressure Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Back Pressure Sensor <--> [Pressure Feedback Exhaust Sensor, EGR] > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 3530 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Fuel Pressure Regulator The fuel pressure test port is a Schrader valve mounted on the fuel pressure regulator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information Fuel Pressure Release: Customer Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information > Page 3540 Fuel Pressure Release: Technician Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3541 Fuel Pressure Release: Service and Repair 1. Remove fuel tank filler cap to relieve any pressure in the tank. CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. 2. When servicing the fuel lines, loosen the fuel fitting to allow any residual fuel line pressure to be relieved. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments Idle Speed: Adjustments Engine idle speed and injection timing are controlled by the Powertrain Control Module (PCM) and are not adjustable. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Injection Timing > System Information > Description and Operation Injection Timing: Description and Operation DESCRIPTION AND OPERATION Fuel Injection Timing is the period of time that the fuel injectors are energized and are controlled by the Powertrain Control Module (PCM). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Engine Control - Poor Acceleration Response Accelerator Pedal Position Sensor: Technical Service Bulletins Engine Control - Poor Acceleration Response Article No. 03-21-6 10/06/03 DRIVEABILITY - ACCELERATOR PEDAL - LACK OF ACCELERATOR CONTROL WHEN MOVING FROM IDLE POSITION - POOR OR NO ENGINE RESPONSE - 7.3L DIT FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 95-10-10 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A lack of accelerator control when moving off of the idle position may occur on some vehicles. The vehicle's engine will be at idle RPM only. This may be caused by the Idle Validation Switch (IVS) contacts not properly closing due to interference of contacts with the switch housing. ACTION Remove and install a revised accelerator pedal assembly which includes IVS. Refer to the appropriate year 7.3L Turbo Diesel Service Manual Supplement, Pages 10-02-2 and 10-02-3, for service procedures. NOTE THE IVS DATE OF MANUFACTURE IS STAMPED NEAR ITS CONNECTOR MATING SURFACE. THE DATE CODE READS AS FOLLOWS: TWO (2) DIGITS FOR CALENDAR YEAR, FOLLOWED BY TWO (2) DIGITS FOR WEEK OF CALENDAR YEAR WHEN MANUFACTURED. FOR EXAMPLE: 9503 INDICATES SWITCH MADE THE THIRD WEEK OF 1995. NOTE ALL SWITCHES WITH A DATE CODE OF 9510 AND LATER HAVE THE CORRECTED SWITCH HOUSING. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-10-10 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 3552 Accelerator Pedal Position Sensor: Specifications Accelerator Pedal Position Sensor 22-28 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 3553 Accelerator Pedal Position Sensor: Locations Full Body View (Part 3 Of 3) The Accelerator Pedal Position Sensor is located behind LH side of instrument panel, above accelerator pedal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor: Description and Operation Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor The Accelerator Pedal (AP) position sensor is a potentiometer that provides a signal to the Powertrain Control Module (PCM) proportional to the accelerator pedal position. The AP position sensor connects to the accelerator pedal shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor > Page 3556 Accelerator Pedal Position Sensor: Description and Operation Idle Validation Switch The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 3557 Accelerator Pedal Position Sensor: Adjustments The Accelerator Pedal (AP) position sensor cannot be adjusted. If service is required, replace accelerator pedal and shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 3558 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor CAUTION: The accelerator pedal assembly is a calibrated unit and must be handled with care. REMOVAL 1. Disconnect the electrical connectors from the Idle Validation Switch (IVS) and the Accelerator Pedal Position (AP) sensor. 2. remove the bolts holding the accelerator pedal and shaft to the instrument panel, 3. Remove the accelerator pedal and sensor assembly from the instrument panel. INSTALLATION 1. Position accelerator pedal and sensor assembly to instrument panel and install lower nut hand tight. 2. Install and tighten accelerator pedal and sensor assembly nuts to 22-28 Nm (17-20 ft lb). 3. Connect the electrical connectors to the IVS and AP sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Tag, disconnect, and position out of the way, any tubes or hoses attached to the air cleaner outlet tube. 2. Loosen clamps as necessary, at both ends of the air cleaner outlet tube. 3. Disconnect and remove air cleaner outlet tube. INSTALLATION Follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation Air Filter Element: Description and Operation AIR INDUCTION SYSTEM Air enters a dry-type engine air cleaner and travels through a pleated, chemically treated, water resistant paper air cleaner element to remove contaminants before entering the engine induction system. The 7.3L Direct Injection (DI) turbo diesel engine also uses a pleated-paper upright type element. Use of other than specific Ford replacement filters may result in significantly shortened filter life and consequent dirt injection. AIR CLEANER ELEMENT Dry-type engine air cleaners are standard on all light truck vehicles. The 7.3L diesel engine also uses a pleated-paper panel type air cleaner element which features an expanding foam filter media attached to the sides of the paper. Use of other than specific Ford replacement air cleaner elements may result in significantly shortened filter life and consequent engine damage. The air cleaner elements should be inspected, and/or replaced periodically according to the maintenance schedule. The air cleaner system has an Intake Air Temperature (IAT) mounted in the outlet hose to monitor engine inlet air temperature. Air Restriction Gauge On diesel engines, replace air cleaner element according to air restriction gauge. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 3566 Air Filter Element: Testing and Inspection Air Restriction Gauge Air Restriction Gauge The 7.3L diesel engine air induction system uses an air restriction indicator to indicate when to change the air cleaner element. The air cleaner element should be replaced when the yellow band in the indicator reaches the CHANGE FILTER mark. Engine performance and fuel economy are adversely affected when maximum restriction is reached. After servicing the air cleaner element, the air restriction indicator can be reset by pushing the button on the end of the indicator. The air restriction indicator is located on the clean-air side of the engine air cleaner. Air Inlet Restriction Check The best method for determining dry-type air cleaner maintenance periods on diesel equipped vehicles is by periodically checking the air restriction indicator. It is recommended that the air restriction indicator be used to determine service intervals. A visual inspection of the air cleaner element will not determine the need for service. Overservicing is not recommended. Air Cleaner Element CAUTION: If the air cleaner element, engine air cleaner or air cleaner outlet tube is removed, use a clean shop rag to prevent contaminants from entering the engine. 1. Replace the air cleaner element according to the maintenance schedule. 2. Check the old air cleaner element. It could help to detect foreign material on the sealing surface that is causing leakage. A streak of dust on the clean air side of the air cleaner element seal is the tell-tale sign. If it exists, be sure the cause is removed before installing a new air cleaner element. 3. Inspect the new air cleaner element for damage. Always look for possible shipping or handling damage. Pay particular attention to the seals. Check for cuts, etc.. Do not use a damaged air cleaner element. 4. Insert the new air cleaner element properly. Cover pressure is not necessary to compress the air cleaner element seal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Description and Operation > Page 3567 Air Filter Element: Service and Repair REMOVAL CAUTION: A special filtering medium is required on Diesel engines. Use only a specific Ford replacement. Use of other Air Cleaner Elements (ACL Element) could result in serious engine damage. Do not attempt to clean ACL Element. Discard and replace. 1. Disconnect and position out of the way any tubes, hoses, or ducts that will interfere with opening the engine Air Cleaner (ACL). CAUTION: Whenever the ACL system is taken apart, use a clean shop rag to prevent contaminants from entering the air intake system. 2. Remove clamps or screws as necessary to remove ACL cover. 3. Remove the ACL cover. 4. Remove the ACL Element, being careful to not loosen any dirt or debris. INSTALLATION 1. Before installing a new ACL Element, check the following items: - Gasket surfaces should be clean and undamaged. - Inlet tube should be clean and undamaged. - ACL Element should be dry and free of holes, ruptures, dents, and damaged gaskets. - Inspect inlet snouts for possible obstructions. 2. Install new ACL Element. 3. Replace upper ACL housing. 4. Attach any tubes, hoses, or ducts as required to upper ACL housing. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow Sensor: Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement > Page 3572 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Diesel MFI Pump Controller > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-15 > Oct > 03 > Engine Control - Misfire, Stall, No Start, DTC P1298 Diesel MFI Pump Controller: Customer Interest Engine Control - Misfire, Stall, No Start, DTC P1298 Article No. 03-21-15 10/06/03 MISS, STALL, NO START - VEHICLE MAY STALL AND NOT RESTART - DIAGNOSTIC TROUBLE CODE (DTC) 1298 MAY BE STORED IN MEMORY-7.3L VEHICLES ONLY VEHICLES BUILT BEFORE 4/11/96 FORD: 1995-1996 ECONOLINE Article 96-19-9 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE Some 7.3L diesel vehicles may exhibit an engine miss where the engine may stall and not restart. Diagnostic Trouble Code (DTC) 1298 may be stored in memory. This may be caused by water intrusion into the Injector Drive Module (IDM). ACTION Replace the IDM and install foam pad around the IDM. The foam pad and the revised IDM should reduce the possibility of water intrusion into the IDM. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Run the injector "buzz" test using New Generation Star (NGS) Tester. If 1DM DTC 1298 is present, replace the IDM with foam installed. 2. Disconnect the vehicle's batteries by disconnecting the ground cable from each battery. 3. Remove the driver's side battery from the vehicle. 4. Remove the Q bottle mounting bolts and swing the bottle inboard and out of the way of the IDM. 5. Disconnect the IDM connectors. 6. Remove the IDM mounting bolt - body side of ground strap. 7. Remove the IDM from the vehicle. Tilt the IDM from side to side and listen for water. If a sloshing sound is heard, replace the IDM with the foam pieces. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Diesel MFI Pump Controller > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-15 > Oct > 03 > Engine Control - Misfire, Stall, No Start, DTC P1298 > Page 3582 8. Install a revised IDM (F7TZ-12B599-AC) with foam installed on the IDM as shown in Figure 1. Be certain to protect the breather vent. 9. Install the IDM back into the vehicle being careful not to disturb the foam. 10. Reinstall the IDM mounting bolt and torque the bolt to 9-11 Nm (77-99 lb-in). 11. Install the IDM connector and torque the bolt to 5-7 Nm (47-63 lb-in). 12. Reinstall the Q bottle and reconnect the batteries. 13. Perform an injector "buzz" test using NGS to verify the repair is complete. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-19-9 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Diesel MFI Pump Controller > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-21-15 > Oct > 03 > Engine Control - Misfire, Stall, No Start, DTC P1298 Diesel MFI Pump Controller: All Technical Service Bulletins Engine Control - Misfire, Stall, No Start, DTC P1298 Article No. 03-21-15 10/06/03 MISS, STALL, NO START - VEHICLE MAY STALL AND NOT RESTART - DIAGNOSTIC TROUBLE CODE (DTC) 1298 MAY BE STORED IN MEMORY-7.3L VEHICLES ONLY VEHICLES BUILT BEFORE 4/11/96 FORD: 1995-1996 ECONOLINE Article 96-19-9 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE Some 7.3L diesel vehicles may exhibit an engine miss where the engine may stall and not restart. Diagnostic Trouble Code (DTC) 1298 may be stored in memory. This may be caused by water intrusion into the Injector Drive Module (IDM). ACTION Replace the IDM and install foam pad around the IDM. The foam pad and the revised IDM should reduce the possibility of water intrusion into the IDM. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Run the injector "buzz" test using New Generation Star (NGS) Tester. If 1DM DTC 1298 is present, replace the IDM with foam installed. 2. Disconnect the vehicle's batteries by disconnecting the ground cable from each battery. 3. Remove the driver's side battery from the vehicle. 4. Remove the Q bottle mounting bolts and swing the bottle inboard and out of the way of the IDM. 5. Disconnect the IDM connectors. 6. Remove the IDM mounting bolt - body side of ground strap. 7. Remove the IDM from the vehicle. Tilt the IDM from side to side and listen for water. If a sloshing sound is heard, replace the IDM with the foam pieces. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Diesel MFI Pump Controller > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-21-15 > Oct > 03 > Engine Control - Misfire, Stall, No Start, DTC P1298 > Page 3588 8. Install a revised IDM (F7TZ-12B599-AC) with foam installed on the IDM as shown in Figure 1. Be certain to protect the breather vent. 9. Install the IDM back into the vehicle being careful not to disturb the foam. 10. Reinstall the IDM mounting bolt and torque the bolt to 9-11 Nm (77-99 lb-in). 11. Install the IDM connector and torque the bolt to 5-7 Nm (47-63 lb-in). 12. Reinstall the Q bottle and reconnect the batteries. 13. Perform an injector "buzz" test using NGS to verify the repair is complete. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-19-9 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Diesel MFI Pump Controller > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diesel MFI Pump Controller: > 9599 > May > 95 > Thermactor System - Buzzing Noise Air Injection Muffler: All Technical Service Bulletins Thermactor System - Buzzing Noise Article No. 95-9-9 05/08/95 ^ THERMACTOR SYSTEM - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY ^ NOISE - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - THERMACTOR SYSTEM OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY LIGHT TRUCK: 1994-95 E-350 ISSUE: A "buzzing" noise may be heard between 25-40 mph while in 2nd or 3rd gear. This may be caused by air flow through the thermactor system during operation in dump mode. ACTION: Replace the air supply bypass valve hose with a cap on the intake air duct and install a thermactor silencer and bracket assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the air dump hose which connects the thermactor bypass valve to the fresh air intake air duct. 2. Cap the open nipple on the intake air duct with a Rubber Cap (C6AZ-9486-A). No clamps are necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Diesel MFI Pump Controller > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diesel MFI Pump Controller: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 3594 3. Install one (1) end of the Air Supply Pump Silencer Hose (F4TZ-9H458-A) onto the Silencer and Bracket Assembly (F4TZ-9H467-B) and secure with a Crimp Clamp (F1HZ-9H447-AA). Refer to Figure 1. 4. Remove the bolt from the engine installed thermactor assembly and install silencer and hose assembly. Refer to Figure 1. 5. Reinstall the bolt and torque to 11-19 N-m (8-14 lb.ft.). No clamp is necessary at the end of the hose. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Diesel MFI Pump Controller > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diesel MFI Pump Controller: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 3595 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950909A Replace Air Dump Hose 0.4 Hr. With Cap And Install Silencer Assembly DEALER CODING CONDITION BASIC PART NO. CODE 9F870 56 OASIS CODES: 403000, 702000, 702300, 703000, 703300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Diesel MFI Pump Controller > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diesel MFI Pump Controller: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 3601 3. Install one (1) end of the Air Supply Pump Silencer Hose (F4TZ-9H458-A) onto the Silencer and Bracket Assembly (F4TZ-9H467-B) and secure with a Crimp Clamp (F1HZ-9H447-AA). Refer to Figure 1. 4. Remove the bolt from the engine installed thermactor assembly and install silencer and hose assembly. Refer to Figure 1. 5. Reinstall the bolt and torque to 11-19 N-m (8-14 lb.ft.). No clamp is necessary at the end of the hose. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diesel MFI Pump > Diesel MFI Pump Controller > Component Information > Technical Service Bulletins > All Other Service Bulletins for Diesel MFI Pump Controller: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 3602 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950909A Replace Air Dump Hose 0.4 Hr. With Cap And Install Silencer Assembly DEALER CODING CONDITION BASIC PART NO. CODE 9F870 56 OASIS CODES: 403000, 702000, 702300, 703000, 703300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns Fuel: Technical Service Bulletins Fuel - Volatility Related Driveability Concerns Article No. 98-26-2 01/04/99 FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED DRIVEABILITY CONCERNS FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94 TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER 1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99 TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350 1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99 VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1990-97 F-700 This TSB article is being republished in its entirety to expand vehicle model coverage and revise the text. ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel. ACTION Refer to the following text for further information. NOTE FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns > Page 3607 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation DESCRIPTION AND OPERATION WARNING: Fuel tank may be pressurized. To remove, rotate cap over 1/2 turn counterclockwise. If cap is venting fuel or a hissing sound is heard, wait until the condition stops before removing the cap. If these precautions are not followed, fuel may spray and cause personal injury. The fuel cap is of a threaded screw-on design with a pre-vent feature that allows the tank to vent for the first three-quarter turn before unthreading. All fuel caps are attached to the vehicle with a tether using the filler pipe-to-housing screw at the three to four o'clock position. The fuel cap assembly provides pressure and vacuum relief functions, and should be replaced with the proper pressure/vacuum relief cap to prevent possible system malfunction. WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information Fuel Pressure Release: Customer Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Customer Safety Information > Page 3616 Fuel Pressure Release: Technician Safety Information CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3617 Fuel Pressure Release: Service and Repair 1. Remove fuel tank filler cap to relieve any pressure in the tank. CAUTION: Fuel supply lines on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. WARNING: Before removing fuel tank filler cap, turn fuel tank filler cap 1/4 to 3/4 turn counterclockwise and wait for tank pressure to relieve. Personal injury may result if fuel tank filler cap is removed without pressure relieved fully. 2. When servicing the fuel lines, loosen the fuel fitting to allow any residual fuel line pressure to be relieved. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter Restriction Sensor > Component Information > Description and Operation Fuel Filter Restriction Sensor: Description and Operation The 7.3L diesel engine is equipped with a fuel filter restriction sensor. A restriction indicator light is provided on the instrument panel (04320) to alert the operator. If the restriction indicator light goes on during normal operation, the fuel filter should be changed as soon as practical. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Heater <--> [Fuel Heater] > Component Information > Locations Fuel Line Heater: Locations The fuel heater is located inside the fuel filter/water separator assembly on top of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Heater <--> [Fuel Heater] > Component Information > Diagrams > Diagram Information and Instructions Fuel Line Heater: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Heater <--> [Fuel Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3626 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Heater <--> [Fuel Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3627 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Heater <--> [Fuel Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3628 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Heater <--> [Fuel Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3629 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Heater <--> [Fuel Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3630 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Heater <--> [Fuel Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3631 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Heater <--> [Fuel Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3632 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Heater <--> [Fuel Heater] > Component Information > Diagrams > Page 3633 Fuel Line Heater: Service and Repair REMOVAL 1. Place a suitable catch container at the end of the drain hose and open the drain. Fuel Filter/Water Separator 2. Using a screwdriver or bar, remove the fuel filter cap. The fuel filter will come out with the cap. 3. Remove and discard the old bevel gasket. Carefully clean the mating surfaces. 4. Disconnect heating element electrical connector. 5. Unscrew stand pipe from inside fuel filter housing. 6. Remove fuel heater element. INSTALLATION 1. Install fuel heater element. 2. Install stand pipe inside housing and tighten securely. 3. Connect heating element electrical connector. 4. Apply a coating of clean diesel fuel to new bevel gasket and install onto housing gland. 5. Place element and cap into housing. Tighten cap until it contacts the aluminum housing. NOTE: The engine will not run if the fuel filter is incorrectly installed in the housing. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector O-Ring > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector O-Ring: > 98-23-13 > Nov > 98 > Diesel Engine - Hesitates/Stalls/Lack of Power/Stumbles Fuel Injector O-Ring: Customer Interest Diesel Engine - Hesitates/Stalls/Lack of Power/Stumbles Article No. 98-23-13 11/23/98 ^ HESITATION/STUMBLE - POOR SEAL ON INJECTOR O-RINGS - 7.3L DI TURBO ^ IDLE - ROUGH - POOR SEAL ON INJECTOR O-RINGS - 7.3L DI TURBO LACK OF POWER/POOR PERFORMANCE - POOR SEAL ON INJECTOR O-RINGS - 7.3L DI TURBO ^ STALLS - POOR SEAL ON INJECTOR 0-RINGS - 7.3L DI TURBO ^ OIL - EXCESSIVE OIL CONSUMPTION - POOR SEAL ON INJECTOR O-RINGS - 7.3L DI TURBO LIGHT TRUCK: 1994-97 F SUPER DUTY 1994-98 F-250 HD, F-350 1995-98 ECONOLINE This TSB article is being republished in its entirety to include vehicles through the 1998 model year. ISSUE On vehicles with a 7.3L direct injection (DI) turbo diesel engine, one or more of the following concerns may be present: ^ Rough Idle ^ Stalling ^ Hesitation/Stumble ^ Loss/Lack of Power ^ Poor Fuel Economy ^ Excessive Oil Consumption These concerns may be caused by the injector cushion 0-rings deteriorating, resulting in a poor seal. This condition cannot be detected with conventional diagnostics (i.e. it will not produce diagnostic codes with either Super Star or New Generation Star Testers). ACTION Remove the injectors, check for deterioration of the cushion 0-ring. If necessary, replace the 0-ring with a new 0-ring which has a more robust design and should not deteriorate under severe conditions. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. If no Diagnostic Trouble Codes (DTCs) are found and normal diagnostics do not lead to a solution, remove the injectors according to the DI Turbo Service Manual. 2. Check for wear or deterioration of the cushion 0-ring. If excessive wear is found, replace the 0-ring with a new blue 0-ring found in the 0-ring kit (F8TZ-9229-AA). Refer to the Instruction Sheet included in the kit. NOTE IF ONE 0-RING IS REPLACED ALL 0-RINGS AND SEALS MUST BE REPLACED. IF ONE INJECTOR SEAL IS SERVICED ALL THE INJECTOR 0-RINGS AND SEALS MUST BE SERVICED. The 0-ring Kit includes the following: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector O-Ring > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector O-Ring: > 98-23-13 > Nov > 98 > Diesel Engine - Hesitates/Stalls/Lack of Power/Stumbles > Page 3643 ^ One (1) upper Backup Ring ^ One (1) upper Cushion Ring ^ One (1) upper Injector Seal ^ One (1) Seal ^ One (1) Lower Injector Seal ^ One (1) Injector Gasket ^ One (1) Instruction Sheet PART NUMBER PART NAME F8TZ-S229-A 0-Ring kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-17-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage, Emissions Warranty Coverage, And Powerstroke Diesel Engine Warranty Coverage OPERATION DESCRIPTION TIME 982313A Replace Injector 0-rings - 5.2 Hrs. F-Series 982313B Replace Injector 0-rings- 4.9 Hrs. Econoline DEALER CODING CONDITION BASIC PART NO. CODE 9A288 D8 OASIS CODES: 401000, 607000, 607400, 608000, 608400, 610000, 610500, 611000, 611500, 614000, 614500 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector O-Ring > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector O-Ring: > 98-23-13 > Nov > 98 > Diesel Engine - Hesitates/Stalls/Lack of Power/Stumbles Fuel Injector O-Ring: All Technical Service Bulletins Diesel Engine - Hesitates/Stalls/Lack of Power/Stumbles Article No. 98-23-13 11/23/98 ^ HESITATION/STUMBLE - POOR SEAL ON INJECTOR O-RINGS - 7.3L DI TURBO ^ IDLE - ROUGH - POOR SEAL ON INJECTOR O-RINGS - 7.3L DI TURBO LACK OF POWER/POOR PERFORMANCE - POOR SEAL ON INJECTOR O-RINGS - 7.3L DI TURBO ^ STALLS - POOR SEAL ON INJECTOR 0-RINGS - 7.3L DI TURBO ^ OIL - EXCESSIVE OIL CONSUMPTION - POOR SEAL ON INJECTOR O-RINGS - 7.3L DI TURBO LIGHT TRUCK: 1994-97 F SUPER DUTY 1994-98 F-250 HD, F-350 1995-98 ECONOLINE This TSB article is being republished in its entirety to include vehicles through the 1998 model year. ISSUE On vehicles with a 7.3L direct injection (DI) turbo diesel engine, one or more of the following concerns may be present: ^ Rough Idle ^ Stalling ^ Hesitation/Stumble ^ Loss/Lack of Power ^ Poor Fuel Economy ^ Excessive Oil Consumption These concerns may be caused by the injector cushion 0-rings deteriorating, resulting in a poor seal. This condition cannot be detected with conventional diagnostics (i.e. it will not produce diagnostic codes with either Super Star or New Generation Star Testers). ACTION Remove the injectors, check for deterioration of the cushion 0-ring. If necessary, replace the 0-ring with a new 0-ring which has a more robust design and should not deteriorate under severe conditions. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. If no Diagnostic Trouble Codes (DTCs) are found and normal diagnostics do not lead to a solution, remove the injectors according to the DI Turbo Service Manual. 2. Check for wear or deterioration of the cushion 0-ring. If excessive wear is found, replace the 0-ring with a new blue 0-ring found in the 0-ring kit (F8TZ-9229-AA). Refer to the Instruction Sheet included in the kit. NOTE IF ONE 0-RING IS REPLACED ALL 0-RINGS AND SEALS MUST BE REPLACED. IF ONE INJECTOR SEAL IS SERVICED ALL THE INJECTOR 0-RINGS AND SEALS MUST BE SERVICED. The 0-ring Kit includes the following: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector O-Ring > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector O-Ring: > 98-23-13 > Nov > 98 > Diesel Engine - Hesitates/Stalls/Lack of Power/Stumbles > Page 3649 ^ One (1) upper Backup Ring ^ One (1) upper Cushion Ring ^ One (1) upper Injector Seal ^ One (1) Seal ^ One (1) Lower Injector Seal ^ One (1) Injector Gasket ^ One (1) Instruction Sheet PART NUMBER PART NAME F8TZ-S229-A 0-Ring kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-17-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage, Emissions Warranty Coverage, And Powerstroke Diesel Engine Warranty Coverage OPERATION DESCRIPTION TIME 982313A Replace Injector 0-rings - 5.2 Hrs. F-Series 982313B Replace Injector 0-rings- 4.9 Hrs. Econoline DEALER CODING CONDITION BASIC PART NO. CODE 9A288 D8 OASIS CODES: 401000, 607000, 607400, 608000, 608400, 610000, 610500, 611000, 611500, 614000, 614500 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Description and Operation Fuel Injector Wiring Harness: Description and Operation The fuel charging wiring connects the engine wire harness to each fuel injector and other electronic engine controls such as the Injection Control Pressure (ICP) sensor, Injection Pressure Regulator (IPR) and Injector Driver Module (IDM). The fuel charging wiring receives fuel injector signals from the Powertrain Control Module (PCM) and transfers the signals to the fuel injectors. The signals from the powertrain control module determine the fuel injection sequence and the duration each fuel injector will stay energized, to allow fuel into the combustion chambers Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Description and Operation > Page 3653 Fuel Injector Wiring Harness: Service and Repair REMOVAL WARNING: Red-striped wires carry 115 volts DC. Severe electrical shock may be received. Do not pierce. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. 1. Disconnect battery ground cable or cables if applicable to multiple battery vehicles. 2. Remove engine cover. 3. Remove valve covers. 4. Disconnect wire connectors from fuel injectors. Glow Plug Connector Removal 5. Using long needle-nose pliers, remove wire connectors from glow plugs. Do not pull on wires when disconnecting glow plug wire connectors. 6. Disconnect wire connector from valve cover gasket using care not to damage valve cover gasket. 7. Remove fuel charging wiring. INSTALLATION 1. Install fuel charging wiring. 2. Connect wire connector to valve cover gasket using care not to damage valve cover gasket. 3. Connect wire connectors to glow plugs. 4. Connect wire connectors to fuel injectors. 5. Install valve covers. 6. Install engine cover. 7. Connect battery ground cable or cables if applicable to multiple battery vehicles. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Specifications Fuel Line Coupler: Specifications Unless otherwise specified use standard torque chart. Torque values are with threads and washer faces coated with engine oil. Torque values are listed without tolerance. Variations to torque will occur due to torque wrench calibration. Variation should be within 10% of nominal values. Standard Torque 1/4 - 20 UNC 9.5 Nm 5/16 - 18 UNC 19 Nm 3/8 - 16 UNC 32 Nm 7/16 - 14 UNC 51 Nm 1/2 - 13 UNC 81 Nm Pipe Threads 1/8 x 27 7-11 Nm 1/4 x 18 17-24 Nm 3/8 x 18 30-44 Nm 1/2 x 14 34-47 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Spring Lock Connector Fuel Line Coupler: Description and Operation Spring Lock Connector DESCRIPTION The spring lock coupling is a fuel line coupling held together by a garter spring inside a circular cage. OPERATION When the coupling is connected, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. As a redundant locking feature, a horseshoe shaped retaining clip is incorporated to improve the retaining reliability of the spring lock coupling. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Spring Lock Connector > Page 3659 Fuel Line Coupler: Description and Operation Push Connect Fittings Push connect fittings are used to make most fuel line connections. Service is not possible if the fitting is damaged, except to replace a damaged retaining clip. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Disconnecting and Connecting Fuel Line Coupler: Service and Repair Disconnecting and Connecting DISCONNECT 1. Release fuel system pressure. 2. Remove retaining clip from spring lock coupling by hand only. Do not use any sharp tool or screwdriver as it may damage the spring lock coupling. 3. Twist fitting to free it from any adhesion at the O-ring seals. 4. Using Spring Lock Coupling Disconnect Tool T81P-19623-G1, or G2, disconnect coupling as follows: a. Fit tool to coupling so tool can enter cage to release garter spring. b. Push the tool into the cage opening to release female fitting from garter spring. c. Pull the coupling male and female fittings apart, with the tool still attached. d. Remove the tool from the coupling. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Disconnecting and Connecting > Page 3662 e. Pull the male and female fittings apart. CONNECT 1. Make sure the garter spring is in cage of male fitting. If garter spring is missing, install a new spring by pushing it into cage opening. If garter spring is damaged, remove it from cage with a small wire hook (do not use a screwdriver) and install a new spring. 2. Clean all dirt or foreign material from both pieces of coupling. WARNING: Use only the specified O-rings as they are made of a special material. The use of any O-ring other than the specified O-ring may allow the connection to leak intermittently during vehicle operation. 3. Replace missing or damaged O-rings. 4. Lubricate male fitting and O-rings and inside of female fitting with clean engine oil XO-10W30-QSP or equivalent meeting Ford specification ESE-M2C153-E. 5. Fit female fitting to male fitting and push, with a slight twisting motion, until garter spring snaps over flared end of female fitting. 6. White indicator ring will pop free of cage on male fitting when joint is fully made. This indicates that garter spring inside cage of male fitting is properly seated over lip of female connector. 7. Ensure coupling engagement by pulling on fitting and visually checking to make sure garter spring is over flared end of female fitting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Disconnecting and Connecting > Page 3663 8. Position retaining clip over metal portion of spring lock coupling. Firmly push retaining clip onto spring lock coupling. Make sure horseshoe portion of clip is over the coupling. Do not install retaining clip over rubber fuel line. 9. START vehicle and check for leaks. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Disconnecting and Connecting > Page 3664 Fuel Line Coupler: Service and Repair Removal and Installation REMOVAL NOTE: Disconnect all push connect fittings from components (sender, 6-way valve) prior to component removal. The push connect fittings that connect flexible fuel lines to the fuel tank sender often cannot be disconnected until the tank is partially lowered, just before removing the fuel tank completely. 1. Inspect the visible internal portion of fitting for dirt accumulation. If more than a light coating of dust is present, clean the fitting before disassembly. 2. Some adhesion between the seals in the fitting and tubing will occur with time. To separate, twist the fitting on the tube, then push and pull the fitting until it moves freely on the tube. 3. Remove "hairpin" type clip from fitting by first bending the shipping tab downward so that it will clear the body. Next (using hands only), spread the two clip legs about 3.0 mm (1/8 inch) each to disengage the body and push the legs into the fitting. Complete removal is accomplished by lightly pulling from the triangular end of the clip and working it clear of the tube and fitting. 4. Grasp the fitting and hose assembly and pull in an axial direction to remove the fitting from the tube. CAUTION: Do not use any tools. 5. When fitting is removed from the tube end, inspect the fitting and tube for any internal parts that may have been dislodged from the fitting. Any loose internal parts should be immediately installed, using the mating tube to insert the parts. INSTALLATION 1. It is recommended that the original retention clip not be reused in the fitting. To install the new clip, insert clip into any two adjacent openings with the triangular portion pointing away from the fitting opening. Install clip to fully engage the body (legs of "hairpin" clip locked on outside of body). Piloting with an index finger is necessary. 2. Before installing the fitting on the tube, wipe tube end with a clean cloth. Inspect the inside of the fitting to make sure it is free of dirt and/or obstructions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Disconnecting and Connecting > Page 3665 3. To install the fitting onto the tube, align the fitting and tube axially and push the fitting onto the tube end. When the fitting is engaged, a definite click will be heard. Pull on fitting to make sure it is fully engaged. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Disconnecting and Connecting > Page 3666 Fuel Line Coupler: Service and Repair Repairing Nylon Push Connectors 1. Relieve fuel system pressure. Read cautionary note prior to relieving pressurized fuel system. If necessary, drain fuel tank. NOTE: Damaged push connectors must be discarded and replaced with new push connectors. If only retaining clip is damaged, replace clip. 2. Disconnect damaged push connector. Be sure to break the tab before removing retaining clip. 3. Select proper size replacement push connector and Ford approved rubber fuel hose. Push Connectors 4. Install hose clamp and proper barbed connector on rubber hose end and tighten clamp. 5. Check that underbody clips are properly securing fuel tubes. 6. Fill fuel tank, START engine and check for fuel leaks. Steel Push Connect Tube Ends 1. Using a tube cutter, remove the damaged push connect tube end at a convenient distance from the end. Allow for adequate room to tighten a union with a wrench. 2. Choose a proper replacement push connect tube end. 3. If required, form the new tube end to the same shape as the damaged tube end which was removed. 4. Select the proper size union and attach the new steel tube end to the original tube. 5. Clean off the steel tube end and replace the push connector onto the tube. (A new retainer clip is recommended.) 6. Check that the underbody clips are properly securing the fuel tubes. 7. START engine and check for leaks. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-27 > Oct > 03 > Fuel System - No Fuel Return Fuel Pressure Regulator: Customer Interest Fuel System - No Fuel Return Article No. 03-21-27 10/06/03 ^ FUEL SYSTEM - 7.3L DIRECT INJECTION (DI) TURBO DIESEL - NO RETURN FUEL FLOW TO FUEL TANK - BEGINNING WITH VEHICLES BUILT 2/9/94 ^ LOW PERFORMANCE/LACK OF POWER - 7.3L DIRECT INJECTION (DI) TURBO DIESEL NO RETURN FUEL FLOW TO FUEL TANK - BEGINNING WITH VEHICLES BUILT 2/9/94 FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 97-11-18 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE Some vehicles may exhibit a lack of power and/or low performance condition, caused by no return fuel flow to the fuel tank. This condition can be identified while performing the "Air in the Fuel System" test from the Performance Diagnostic Sheet. This is due to a restricted orifice or clogged strainer screen. This TSB article does not apply to 1996 and later vehicles. ACTION Remove the fuel pressure regulator assembly to inspect the return orifice and strainer screen for debris. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to Figure 1. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-27 > Oct > 03 > Fuel System - No Fuel Return > Page 3675 1. Remove fuel filter cap and filter element. 2. Disconnect the two (2) flexible return fuel hose fittings, fuel bypass hose, and two (2) attaching bolts. 3. Remove regulator assembly from fuel filter housing, taking care not to damage 0-ring which will be used for reinstallation. 4. Unscrew strainer assembly from regulator. 5. Remove orifice and check ball from regulator. 6. Inspect orifice screen (which may remain in filter housing where regulator was removed), orifice, check ball and strainer screen for debris. 7. Clean any contamination from parts using disc brake cleaner. 8. Reassemble all components and verify return fuel flow is now present. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-11-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-21-27 > Oct > 03 > Fuel System - No Fuel Return Fuel Pressure Regulator: All Technical Service Bulletins Fuel System - No Fuel Return Article No. 03-21-27 10/06/03 ^ FUEL SYSTEM - 7.3L DIRECT INJECTION (DI) TURBO DIESEL - NO RETURN FUEL FLOW TO FUEL TANK - BEGINNING WITH VEHICLES BUILT 2/9/94 ^ LOW PERFORMANCE/LACK OF POWER - 7.3L DIRECT INJECTION (DI) TURBO DIESEL NO RETURN FUEL FLOW TO FUEL TANK - BEGINNING WITH VEHICLES BUILT 2/9/94 FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 97-11-18 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE Some vehicles may exhibit a lack of power and/or low performance condition, caused by no return fuel flow to the fuel tank. This condition can be identified while performing the "Air in the Fuel System" test from the Performance Diagnostic Sheet. This is due to a restricted orifice or clogged strainer screen. This TSB article does not apply to 1996 and later vehicles. ACTION Remove the fuel pressure regulator assembly to inspect the return orifice and strainer screen for debris. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to Figure 1. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-21-27 > Oct > 03 > Fuel System - No Fuel Return > Page 3681 1. Remove fuel filter cap and filter element. 2. Disconnect the two (2) flexible return fuel hose fittings, fuel bypass hose, and two (2) attaching bolts. 3. Remove regulator assembly from fuel filter housing, taking care not to damage 0-ring which will be used for reinstallation. 4. Unscrew strainer assembly from regulator. 5. Remove orifice and check ball from regulator. 6. Inspect orifice screen (which may remain in filter housing where regulator was removed), orifice, check ball and strainer screen for debris. 7. Clean any contamination from parts using disc brake cleaner. 8. Reassemble all components and verify return fuel flow is now present. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-11-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Pressure Regulator: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 3692 Fuel Pressure Regulator: Specifications Injection Pressure Regulator 47 Nm Injection Control Pressure Solenoid Nut 6 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 3693 Fuel Pressure Regulator: Locations The fuel pressure regulator is located on the side of the fuel filter. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 3694 Fuel Pressure Regulator: Description and Operation DESCRIPTION AND OPERATION Fuel Pressure Regulator Fuel pressure in the cylinder head fuel galleries is maintained at 275 kPa (40 psi) by a fuel pressure regulator. Excess fuel from the cylinder head fuel galleries is routed to the fuel pressure regulator through special rubber compound hoses from the front of each cylinder head. The hoses absorb and smooth pressure pulses from the piston stage of the fuel pump. NOTE: Only certified replacement hoses with the correct part number should be used when repairing the fuel system. Any other hoses may not provide the pressure and flexibility required for proper fuel system operation. CONSTRUCTION The fuel pressure regulator contains a spring-loaded spool valve which opens to allow excess fuel to exit the cylinder head fuel galleries. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 3695 Fuel Pressure Regulator: Service and Repair REMOVAL 1. Remove engine cover. 2. Remove turbocharger. 3. Remove fuel filter assembly. High Pressure Oil Pump Components 4. Disconnect wire connector from injection control pressure solenoid. 5. Remove nut securing injection control pressure solenoid to injection pressure regulator. 6. Remove injection control pressure solenoid. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 3696 7. Remove injection pressure regulator from high pressure oil pump. INSTALLATION 1. Install injection pressure regulator to high pressure oil pump. Tighten injection pressure regulator to 47 Nm (35 ft lb). 2. Install injection control pressure solenoid. Tighten injection control pressure solenoid nut to 6 Nm (53 in lb). 3. Connect wire connector to injection control pressure solenoid. 4. Install fuel filter assembly. 5. Install turbocharger. 6. Install engine cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Injection Control Pressure Sensor (ICP) <--> [Fuel Pressure Sensor/Switch] > Component Information > Locations Injection Control Pressure Sensor (ICP): Locations Sensor And Actuator Locations The Injection Control Pressure (ICP) is located in the cylinder head oil gallery. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Injection Control Pressure Sensor (ICP) <--> [Fuel Pressure Sensor/Switch] > Component Information > Locations > Page 3700 Injection Control Pressure Sensor (ICP): Description and Operation Injection Control Pressure Sensor The Injection Control Pressure (ICP) sensor is a variable capacitance sensor that, when supplied with a 5-volt reference signal from the Powertrain Control Module (PCM), produces a linear analog voltage signal that indicates oil pressure. The ICP sensor provides a feedback signal to indicate high pressure oil so that the PCM can command the correct injector timing, pulse width and injection control pressure for proper fuel delivery at all speed and load conditions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Injection Control Pressure Sensor (ICP) <--> [Fuel Pressure Sensor/Switch] > Component Information > Locations > Page 3701 Injection Control Pressure Sensor (ICP): Service and Repair Injection Control Pressure Sensor REMOVAL 1. Disconnect Injection Control Pressure (ICP) sensor electrical connector. 2. Remove ICP sensor. INSTALLATION 1. Install ICP sensor. 2. Connect sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Fuel Pressure Regulator The fuel pressure test port is a Schrader valve mounted on the fuel pressure regulator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations Fuel Pressure Test Port: Locations Fuel Pressure Regulator The fuel pressure test port is a Schrader valve mounted on the fuel pressure regulator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Control Unit: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3714 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3715 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3716 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3717 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3718 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3719 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3720 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Recalls: > NHTSA98V062000 > Mar > 98 > Recall 98V062000: Possible Fuel Line Leakage Fuel Return Line: Recalls Recall 98V062000: Possible Fuel Line Leakage Year: 1995 Make: FORD TRUCK Model: ECONOLINE Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 20000 Summary: Vehicle Description: Light duty passenger vans and stripped chassis. There is interference between the parking brake cable and the fuel line which, over time, can result in damage to the fuel line causing fuel leakage. If there is fuel leakage in the presence of an ignition source, fire could result. Dealers will replace the fuel supply line. In addition, a piece of anti-abrasion insulation will be installed to prevent abrasion of the fuel line. Owner notification is expected to begin April 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA98V062000 > Mar > 98 > Recall 98V062000: Possible Fuel Line Leakage Fuel Return Line: All Technical Service Bulletins Recall 98V062000: Possible Fuel Line Leakage Year: 1995 Make: FORD TRUCK Model: ECONOLINE Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 20000 Summary: Vehicle Description: Light duty passenger vans and stripped chassis. There is interference between the parking brake cable and the fuel line which, over time, can result in damage to the fuel line causing fuel leakage. If there is fuel leakage in the presence of an ignition source, fire could result. Dealers will replace the fuel supply line. In addition, a piece of anti-abrasion insulation will be installed to prevent abrasion of the fuel line. Owner notification is expected to begin April 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Return Line: > 96114 > May > 96 > Center Wheel Ornament - Falls Off Wheel Cover: All Technical Service Bulletins Center Wheel Ornament - Falls Off Article No. 96-11-4 05/20/96 ^ TRIM - EXTERIOR - CENTER WHEEL ORNAMENT FALLING OFF - VEHICLES BUILT THROUGH 12/8/95 WITH 16 INCH WHEELS ^ WHEELS - CENTER WHEEL ORNAMENT FALLING OFF - VEHICLES BUILT THROUGH 12/8/95 WITH 16 INCH WHEELS LIGHT TRUCK: 1995-96 E-25O, E-35O, F-25O, F-350 ISSUE: The center wheel ornament may fall off of the wheel(s) while driving. This may be caused by broken retention clips, poor clip retention and/or improper installation. ACTION: Remove any existing center wheel ornaments and replace all four (4) of the center wheel ornaments using the wheel ornament kit. The new ornaments have improved clip retention and an easier installation procedure to reduce the possibility of improper installation. Make sure the ornament is centered and pressed on evenly around the outside edge with both hands. Do not hit the ornament to install it as this may damage the ornament. PART NUMBER PART NAME F5UZ-1A108-VB Wheel Ornament Kit (E-250 SRW With Semi-Float Axle) F5TZ-1A108-XB Wheel Ornament Kit (E/F-250-35O 4X2 With Full-Float Axle) F5TZ-1A108-UB Wheel Ornament Kit (F-250/350 4X4 SRW) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961104A Replace Wheel Ornaments 0.4 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1130 02 OASIS CODES: 108000, 306000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Page 3744 Fuel Return Line: Specifications Fuel Tube Organizer Clip Nuts 8-10 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Page 3745 Fuel Return Line: Description and Operation The fuel lines used are mostly of stainless steel tubing and flexible teflon lines with steel push connectors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Page 3746 Fuel Return Line: Testing and Inspection If fuel lines are suspected of contamination or leaks, inspect lines for cracks and fittings for leaks. Replace any lines that are damaged. If fuel line contains contaminated fuel, flush with clean diesel fuel, drain fuel filter, and inspect filter element. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Remove, Repair, and Install Fuel Return Line: Service and Repair Remove, Repair, and Install REMOVAL NOTE: Fuel supply tubes and the various fuel lines need not be serviced as assemblies. They may be cut, squared and formed out of rolls of fuel system service tubing and hose material available at dealerships, or a service part may be purchased. A damaged section of tubing longer than 305 mm (12 inches) can be cut out of the existing line and replaced by a comparable service tubing section, spliced into the line by means of connecting hoses and retaining clamps. A damaged section of tubing shorter than 305 mm (12 inches) can be cut out of the line and replaced by a length of service hose and two retaining clamps. All replacement hoses must be cut to a length and inside diameter that will ensure proper clamp retention. Front Fuel Lines Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Remove, Repair, and Install > Page 3749 Rear Fuel Lines 1. Disconnect the damaged line at both ends. 2. Remove the line from the holding clips along the frame. 3. Remove all damaged hose and tube sections. INSTALLATION 1. Cut a new section of steel tubing to approximately the same length and inside diameter as the section to be replaced. Allow extra length for flaring the ends of the tubing where required. Square the ends of the cut tubing with a file. 2. Ream the inside edges of the cut tubing with the reamer blade on the tube cutter. Be sure metal chips are removed from inside the tube(s). Double flare the ends of the cut tubing, as required. 3. Bend the tube section to conform to the contour of the original tube. Cut an ample length of hose to form a coupling between the ends of the fuel lines. Connect the hose couplings to the tubing and install the retaining clamps. 4. Position the lines in the clips. Connect the lines and check for leaks. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Remove, Repair, and Install > Page 3750 Fuel Return Line: Service and Repair Repairing Front Fuel Lines Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Remove, Repair, and Install > Page 3751 Rear Fuel Lines CAUTION: Fuel lines cannot be repaired if damaged, the component must be replaced. CAUTION: Plastic fuel tube must not be repaired using hose and hose clamps. Push connect fittings cannot be repaired except to replace the retaining clips. Should the plastic tubes, push connect fittings or mating tube ends become damaged and leak, approved service parts must be used to service the fuel lines. CAUTION: The fuel lines can be damaged by torches, welding sparks, grinding and other operations which involve heat and high temperatures. If any repair or service operation will be used which involves heat and high temperatures, locate all fuel system components, especially the plastic fuel lines to be certain they will not be damaged. It is recommended that the plastic fuel tubes be removed from the vehicle if a torch or high heat producing equipment is to be used for service in the following areas: 1. Exhaust or suspension components in proximity to fuel tubes. 2. Underbody frames, rails and crossmembers (left side). 3. Dash panel, under vehicle or inside the passenger compartment (lower left side). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Remove, Repair, and Install > Page 3752 Fuel Return Line: Service and Repair Fuel Tube Organizer REMOVAL Typical Organizer Assembly NOTE: Either single lines and hoses may be removed from organizer assemblies or the entire assembly may be removed. To Remove A Single Line Or Hose: 1. Snap open organizer-to-frame clips. 2. Disconnect line or hose ends. 3. Snap line or hose out of organizer plastic core and remove. It may be necessary to remove some other lines to get one out. To Remove The Entire Assembly: 1. Disconnect battery ground cable. 2. Disconnect all lines, hoses, and electrical connections going through organizer. 3. Remove nuts retaining organizer assembly to frame. 4. Remove assembly. INSTALLATION To Install Assembly: 1. Position organizer assembly on frame. 2. Install organizer clip nuts and tighten to 8-10 Nm (71-89 in lb). 3. Connect all hoses, lines, and wires. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing Technical Service Bulletin # 98S08 Date: 980501 Recall - Rear Fuel Supply Line Chafing SAFETY RECALL 98S08 Certain 1995 Model Year E-250/350 Stripped and Cutaway Econoline Chassis- Rear Fuel Supply Line Chafing ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3761 Attachment I - Administrative OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires that dealers complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Affected vehicles which are brought to your dealership. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3762 WARRANTY AND POLICY MANUAL See Sections 5 and 6 of the ACESII Manual. REFUNDS See ACESII Manual, Section 3. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted below: MEMO PART (Not required on all vehicles) (Order only if inspection reveals damage or leaking fuel line.) Please Note: We Expect less than 10% of affected vehicles to require fuel line replacement. Please do not place excessive advance orders for the fuel line assembly (F8UZ-9S297-BA). DEALER PRICE For latest prices check or call your: ^ Order Processing Center ^ DOES II Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3763 ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Affected Vehicles 1995 MODEL YEAR ECONOLINE CUTAWAY AND STRIPPED CHASSIS MODELS BUILT FROM AUGUST 15, 1994 THROUGH MARCH 1, 1995 (WITHOUT FRAME MODIFICATIONS) WARNING DO NOT SMOKE, CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN FUELING THE VEHICLE OR WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH A BLINDNESS. WARNING ALLOWING ANY FUEL TO GET IN YOUR EYES WILL CAUSE SEVERE IRRITATION. FAILURE TO SEEK PROPER MEDICAL ATTENTION FOR FUEL CONTACT WITH THE EYES COULD LEAK TO PERMANENT INJURY SUCH AS BLINDNESS. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. MAKE SURE YOU WASH YOUR HANDS BEFORE HANDLING FOOD. WARNING DO NOT OPERATE ENGINE WHILE REFUELING. Service Procedure 1. Open hood or remove engine cover to allow access to fuel pressure relief valve. 2. Relieve fuel system pressure as follows: ^ Connect Multiport Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B to fuel pressure relief valve on the fuel supply manifold. ^ Open manual valve on gauge to relieve fuel system pressure. ^ Remove gauge from relief valve. 3. Raise and support vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3764 4. Disconnect and separate fuel supply, return and vapor lines from left frame rail. See Figure 1. 5. Route fuel lines back behind rear axle for inspection purposes.See Figure 2. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3765 6. Check fuel supply (blue) line for fraying of braided reinforcement.See Figure 3. If fuel line braiding is damaged, the fuel line must be replaced (F8UZ-9S297-BA). Proceed to next step. If fuel line braiding is not damaged, proceed to step 23. 7. Drain fuel tank. 8. Support fuel tank with adjustable jack. 9. Remove fuel tank straps retaining bolts. 10. Slightly lower fuel tank. 11. Disconnect fuel filler and vent hoses from fuel tank. 12. Disconnect fuel pump electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3766 13. Disconnect fuel supply line from top of fuel tank. Refer to Figure 4. 14. Unclip fuel supply line from 3-tube clip. See Figure 4. 15. Remove fuel supply line from vehicle. 16. Install new fuel supply line into vehicle. 17. Clip fuel supply line into 3-tube clip. 18. Connect fuel supply line to top of fuel tank. 19. Connect fuel pump electrical connector. 20. Connect fuel filler and vent hoses. 21. Raise fuel tank to installed position. 22. Install fuel tank straps retaining bolts. Tighten bolts to 87-119 Nm (64-88 lb/ft). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3767 23. Clip wiring harness in bottom clip of frame rail organizer. See Figure 5. 24. Connect fuel supply, return and vapor lines. 25. Clip fuel supply, return and vapor lines into organizer assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3768 26. Bundle fuel supply, return and vapor lines to wiring harness using convolute and tie straps.See Figure 6. Make sure there is clearance between convolute bundle and parking brake cable. 27. Lower vehicle. 28. Start and run engine. 29. Raise vehicle 30. Inspect fuel system for leaks. 31. Lower vehicle. 32. Install engine cover, if necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3769 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3770 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls for Fuel Supply Line: > NHTSA98V062000 > Mar > 98 > Recall 98V062000: Possible Fuel Line Leakage Fuel Supply Line: Recalls Recall 98V062000: Possible Fuel Line Leakage Year: 1995 Make: FORD TRUCK Model: ECONOLINE Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 20000 Summary: Vehicle Description: Light duty passenger vans and stripped chassis. There is interference between the parking brake cable and the fuel line which, over time, can result in damage to the fuel line causing fuel leakage. If there is fuel leakage in the presence of an ignition source, fire could result. Dealers will replace the fuel supply line. In addition, a piece of anti-abrasion insulation will be installed to prevent abrasion of the fuel line. Owner notification is expected to begin April 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing Technical Service Bulletin # 98S08 Date: 980501 Recall - Rear Fuel Supply Line Chafing SAFETY RECALL 98S08 Certain 1995 Model Year E-250/350 Stripped and Cutaway Econoline Chassis- Rear Fuel Supply Line Chafing ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3780 Attachment I - Administrative OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires that dealers complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Affected vehicles which are brought to your dealership. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3781 WARRANTY AND POLICY MANUAL See Sections 5 and 6 of the ACESII Manual. REFUNDS See ACESII Manual, Section 3. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channel as noted below: MEMO PART (Not required on all vehicles) (Order only if inspection reveals damage or leaking fuel line.) Please Note: We Expect less than 10% of affected vehicles to require fuel line replacement. Please do not place excessive advance orders for the fuel line assembly (F8UZ-9S297-BA). DEALER PRICE For latest prices check or call your: ^ Order Processing Center ^ DOES II Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3782 ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Affected Vehicles 1995 MODEL YEAR ECONOLINE CUTAWAY AND STRIPPED CHASSIS MODELS BUILT FROM AUGUST 15, 1994 THROUGH MARCH 1, 1995 (WITHOUT FRAME MODIFICATIONS) WARNING DO NOT SMOKE, CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN FUELING THE VEHICLE OR WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH A BLINDNESS. WARNING ALLOWING ANY FUEL TO GET IN YOUR EYES WILL CAUSE SEVERE IRRITATION. FAILURE TO SEEK PROPER MEDICAL ATTENTION FOR FUEL CONTACT WITH THE EYES COULD LEAK TO PERMANENT INJURY SUCH AS BLINDNESS. WARNING IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. MAKE SURE YOU WASH YOUR HANDS BEFORE HANDLING FOOD. WARNING DO NOT OPERATE ENGINE WHILE REFUELING. Service Procedure 1. Open hood or remove engine cover to allow access to fuel pressure relief valve. 2. Relieve fuel system pressure as follows: ^ Connect Multiport Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B to fuel pressure relief valve on the fuel supply manifold. ^ Open manual valve on gauge to relieve fuel system pressure. ^ Remove gauge from relief valve. 3. Raise and support vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3783 4. Disconnect and separate fuel supply, return and vapor lines from left frame rail. See Figure 1. 5. Route fuel lines back behind rear axle for inspection purposes.See Figure 2. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3784 6. Check fuel supply (blue) line for fraying of braided reinforcement.See Figure 3. If fuel line braiding is damaged, the fuel line must be replaced (F8UZ-9S297-BA). Proceed to next step. If fuel line braiding is not damaged, proceed to step 23. 7. Drain fuel tank. 8. Support fuel tank with adjustable jack. 9. Remove fuel tank straps retaining bolts. 10. Slightly lower fuel tank. 11. Disconnect fuel filler and vent hoses from fuel tank. 12. Disconnect fuel pump electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3785 13. Disconnect fuel supply line from top of fuel tank. Refer to Figure 4. 14. Unclip fuel supply line from 3-tube clip. See Figure 4. 15. Remove fuel supply line from vehicle. 16. Install new fuel supply line into vehicle. 17. Clip fuel supply line into 3-tube clip. 18. Connect fuel supply line to top of fuel tank. 19. Connect fuel pump electrical connector. 20. Connect fuel filler and vent hoses. 21. Raise fuel tank to installed position. 22. Install fuel tank straps retaining bolts. Tighten bolts to 87-119 Nm (64-88 lb/ft). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3786 23. Clip wiring harness in bottom clip of frame rail organizer. See Figure 5. 24. Connect fuel supply, return and vapor lines. 25. Clip fuel supply, return and vapor lines into organizer assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3787 26. Bundle fuel supply, return and vapor lines to wiring harness using convolute and tie straps.See Figure 6. Make sure there is clearance between convolute bundle and parking brake cable. 27. Lower vehicle. 28. Start and run engine. 29. Raise vehicle 30. Inspect fuel system for leaks. 31. Lower vehicle. 32. Install engine cover, if necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3788 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 98S08 > May > 98 > Recall - Rear Fuel Supply Line Chafing > Page 3789 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > NHTSA98V062000 > Mar > 98 > Recall 98V062000: Possible Fuel Line Leakage Fuel Supply Line: All Technical Service Bulletins Recall 98V062000: Possible Fuel Line Leakage Year: 1995 Make: FORD TRUCK Model: ECONOLINE Year of Recall: '98 Type of Report: Vehicle Potential Number of Units Affected: 20000 Summary: Vehicle Description: Light duty passenger vans and stripped chassis. There is interference between the parking brake cable and the fuel line which, over time, can result in damage to the fuel line causing fuel leakage. If there is fuel leakage in the presence of an ignition source, fire could result. Dealers will replace the fuel supply line. In addition, a piece of anti-abrasion insulation will be installed to prevent abrasion of the fuel line. Owner notification is expected to begin April 20, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Page 3794 Fuel Supply Line: Specifications Fuel Tube Organizer Clip Nuts 8-10 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Page 3795 Fuel Supply Line: Description and Operation The fuel lines used are mostly of stainless steel tubing and flexible teflon lines with steel push connectors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Page 3796 Fuel Supply Line: Testing and Inspection If fuel lines are suspected of contamination or leaks, inspect lines for cracks and fittings for leaks. Replace any lines that are damaged. If fuel line contains contaminated fuel, flush with clean diesel fuel, drain fuel filter, and inspect filter element. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Remove, Repair, and Install Fuel Supply Line: Service and Repair Remove, Repair, and Install REMOVAL NOTE: Fuel supply tubes and the various fuel lines need not be serviced as assemblies. They may be cut, squared and formed out of rolls of fuel system service tubing and hose material available at dealerships, or a service part may be purchased. A damaged section of tubing longer than 305 mm (12 inches) can be cut out of the existing line and replaced by a comparable service tubing section, spliced into the line by means of connecting hoses and retaining clamps. A damaged section of tubing shorter than 305 mm (12 inches) can be cut out of the line and replaced by a length of service hose and two retaining clamps. All replacement hoses must be cut to a length and inside diameter that will ensure proper clamp retention. Front Fuel Lines Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Remove, Repair, and Install > Page 3799 Rear Fuel Lines 1. Disconnect the damaged line at both ends. 2. Remove the line from the holding clips along the frame. 3. Remove all damaged hose and tube sections. INSTALLATION 1. Cut a new section of steel tubing to approximately the same length and inside diameter as the section to be replaced. Allow extra length for flaring the ends of the tubing where required. Square the ends of the cut tubing with a file. 2. Ream the inside edges of the cut tubing with the reamer blade on the tube cutter. Be sure metal chips are removed from inside the tube(s). Double flare the ends of the cut tubing, as required. 3. Bend the tube section to conform to the contour of the original tube. Cut an ample length of hose to form a coupling between the ends of the fuel lines. Connect the hose couplings to the tubing and install the retaining clamps. 4. Position the lines in the clips. Connect the lines and check for leaks. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Remove, Repair, and Install > Page 3800 Fuel Supply Line: Service and Repair Repairing Front Fuel Lines Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Remove, Repair, and Install > Page 3801 Rear Fuel Lines CAUTION: Fuel lines cannot be repaired if damaged, the component must be replaced. CAUTION: Plastic fuel tube must not be repaired using hose and hose clamps. Push connect fittings cannot be repaired except to replace the retaining clips. Should the plastic tubes, push connect fittings or mating tube ends become damaged and leak, approved service parts must be used to service the fuel lines. CAUTION: The fuel lines can be damaged by torches, welding sparks, grinding and other operations which involve heat and high temperatures. If any repair or service operation will be used which involves heat and high temperatures, locate all fuel system components, especially the plastic fuel lines to be certain they will not be damaged. It is recommended that the plastic fuel tubes be removed from the vehicle if a torch or high heat producing equipment is to be used for service in the following areas: 1. Exhaust or suspension components in proximity to fuel tubes. 2. Underbody frames, rails and crossmembers (left side). 3. Dash panel, under vehicle or inside the passenger compartment (lower left side). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Remove, Repair, and Install > Page 3802 Fuel Supply Line: Service and Repair Fuel Tube Organizer REMOVAL Typical Organizer Assembly NOTE: Either single lines and hoses may be removed from organizer assemblies or the entire assembly may be removed. To Remove A Single Line Or Hose: 1. Snap open organizer-to-frame clips. 2. Disconnect line or hose ends. 3. Snap line or hose out of organizer plastic core and remove. It may be necessary to remove some other lines to get one out. To Remove The Entire Assembly: 1. Disconnect battery ground cable. 2. Disconnect all lines, hoses, and electrical connections going through organizer. 3. Remove nuts retaining organizer assembly to frame. 4. Remove assembly. INSTALLATION To Install Assembly: 1. Position organizer assembly on frame. 2. Install organizer clip nuts and tighten to 8-10 Nm (71-89 in lb). 3. Connect all hoses, lines, and wires. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3803 Fuel Supply Line: Tools and Equipment 3/8" Fuel Line Remover AST tool# 8013 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3804 Used for removing 3/8" fuel lines and feed lines from the fuel pump-sending unit. - For R and R of Fuel and Feed Lines - Quick line removal - Gold-Anodized Aluminum Construction - See Application Chart - Included in the 8100, 8107 and #8110 Line Disconnect Sets. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: 8110 - 10-Pc. Line Disconnect Set Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3805 8107 - 7-Piece Line Disconnect Set Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Specifications Fuel Filler Hose: Specifications Filler Hose and Vent Hose Clamps 3-4 Nm Filler Pipe to Body Screws 2-3 Nm Filler Pipe to Support Bracket Clamps 3-4 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > With Aft-of-Axle Tank Fuel Filler Hose: Service and Repair With Aft-of-Axle Tank REMOVAL 1. Disconnect battery ground cables and siphon the fuel from the tank using Rotunda Fuel Storage Tanker 034-00002 or equivalent. 2. Remove the three retainer screws that attach the filler pipe flange to the body fuel filler pipe housing. 3. Loosen the clamps that attach the filler pipe to the fuel filler hose and the fuel vent hose. Disconnect the hoses. 4. Remove hex bolt to frame to disconnect fuel fill tube ground strap. 5. Loosen the clamp that attaches the filler pipe to the support bracket at the underbody flange (if present). 6. Remove the fuel filler pipe assembly by rotating it through the opening in the underbody below the body housing assembly. INSTALLATION 1. Install the fuel filler pipe assembly by inserting it through the underbody opening and rotating it to butt the pipe flange against the body side panel bracket. 2. Attach the pipe flange to the body side panel bracket with three retaining screws. Tighten screws to 2-3 Nm (18-27 in lb). 3. Tighten the clamps that attach the filler pipe to the fuel tube support bracket at the underbody flange to 3-4 Nm (27-35 in lb) (if present). 4. Connect the fuel filler hose and the fuel vent hose to the fuel filler assembly. Tighten the attaching clamps to 3-4 Nm (27-35 in lb). 5. Fill the tank, install fuel tank filler cap, and check all connections for leaks. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > With Aft-of-Axle Tank > Page 3812 Fuel Filler Hose: Service and Repair With Midship Tank REMOVAL 1. Disconnect battery ground cables and siphon the fuel from the tank using Rotunda Fuel Storage Tanker 034-00002 or equivalent. 2. Remove the three retainer screws that attach the filler pipe flange to the body fuel filler pipe housing. 3. Loosen the clamps that attach the filler pipe to the fuel filler hose and the fuel vent hose. Disconnect the hoses. 4. Remove hex bolt to frame to disconnect fuel fill tube ground strap. 5. Loosen the clamp that attaches the filler pipe to the support bracket at the underbody flange (if present). 6. Remove the fuel filler pipe assembly by rotating it through the opening in the underbody below the body housing assembly. INSTALLATION 1. Install the fuel filler pipe assembly by inserting it through the underbody opening and rotating it to butt the pipe flange against the body side panel bracket. 2. Attach the pipe flange to the body side panel bracket with three retaining screws. Tighten screws to 2-3 Nm (18-27 in lb). 3. Tighten the clamps that attach the filler pipe to the fuel tube support bracket at the underbody flange to 3-4 Nm (27-35 in lb) (if present). 4. Connect the fuel filler hose and the fuel vent hose to the fuel filler assembly. Tighten the attaching clamps to 3-4 Nm (27-35 in lb). 5. Fill the tank, install fuel tank filler cap, and check all connections for leaks. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair Fuel Tank Mounting Straps: Service and Repair REMOVAL 1. Raise the vehicle on hoist. 2. Remove skid plate bolts and skid plate, if equipped. 3. Position suitable jack under tank for support. 4. Remove fuel tank support strap nuts. 5. Remove fuel tank support strap. INSTALLATION 1. Install fuel tank support strap. 2. Install fuel tank support strap nuts and tighten. 3. Remove jack from under tank. 4. Install skid plate bolts and skid plate. 5. Lower the vehicle from the hoist. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications Fuel Tank Unit: Specifications Sending Unit Retaining Screws 9-11 Nm Plastic Locking Ring 54-75 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Specifications > Page 3819 Fuel Tank Unit: Description and Operation DESCRIPTION AND OPERATION The fuel tank sending unit supplies varying voltage readings to the fuel gauge to indicate the amount of fuel remaining in the fuel tank. The voltage readings vary directly in proportion to the fuel level. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Secured With Metal Locking Ring Fuel Tank Unit: Service and Repair Secured With Metal Locking Ring REMOVAL 1. Remove the fuel tank. 2. Position fuel tank on a workbench and remove any dirt that has accumulated around the sender so that it will not enter the fuel tank. 3. Turn the fuel sending unit locking ring counterclockwise with Fuel Tank Sender Wrench T74P-9275-A and remove locking ring. 4. Remove the fuel tank sending unit from the fuel tank. 5. Remove seal gasket and discard. INSTALLATION 1. Clean the fuel tank sending unit mounting flange and the fuel tank mounting surface and seal ring groove. 2. Put a light coating of Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B grease on a new seal ring to hold it in place during assembly and install it in the fuel ring groove. 3. Install fuel tank sending unit assembly carefully. Be sure that the tabs of the sender are positioned into slots of the fuel tank. Make sure ring remains in place. 4. Hold the fuel tank sending unit and sealing gasket in place, install and rotate the locking ring clockwise until the stop is against the retainer ring tab. 5. Install fuel tank. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Secured With Metal Locking Ring > Page 3822 Fuel Tank Unit: Service and Repair Secured With Screws REMOVAL 1. Remove the fuel tank. 2. Position fuel tank on a workbench and remove any dirt that has accumulated around the sender so that it will not enter the fuel tank. 3. Remove the screws securing the fuel tank sending unit. 4. Remove the fuel tank sending unit from the fuel tank. 5. Remove seal gasket and discard. INSTALLATION 1. Clean the fuel tank sending unit mounting flange and the fuel tank mounting surface and seal ring groove. 2. Put a light coating of Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B grease on a new seal ring to hold it in place during assembly. 3. Install fuel tank sending unit assembly carefully. Be sure that the tabs of the sender are positioned into slots of the fuel tank. 4. Hold the fuel tank sending unit and sealing gasket in place by the screws, tighten the sending unit retaining screws to 9-11 Nm (80-97 in lb). 5. Install fuel tank. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Secured With Metal Locking Ring > Page 3823 Fuel Tank Unit: Service and Repair Secured With Plastic Locking Ring REMOVAL 1. Remove the fuel tank. 2. Position fuel tank on a workbench and remove any dirt that has accumulated around the sender so that it will not enter the fuel tank. 3. Turn the fuel sending unit locking ring counterclockwise and remove locking ring. 4. Remove the fuel tank sending unit from the fuel tank. 5. Remove seal gasket and discard. INSTALLATION 1. Clean the fuel tank sending unit mounting flange and the fuel tank mounting surface and seal ring groove. 2. Put a light coating of Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B grease on a new seal ring to hold it in place during assembly and install it in the fuel ring groove. 3. Install fuel tank sending unit assembly carefully. Be sure that the tabs of the sender are positioned into slots of the fuel tank. Make sure ring remains in place. 4. Hold the fuel tank sending unit and sealing gasket in place, install and rotate the locking ring clockwise until the stop is against the retainer ring tab. 5. Install fuel tank. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > Customer Interest for Fuel/Water Separator: > 03-21-8 > Oct > 03 > Fuel System - Water in Fuel Lamp Illuminated Constantly Fuel/Water Separator: Customer Interest Fuel System - Water in Fuel Lamp Illuminated Constantly Article No. 03-21-8 10/06/03 ^ WATER IN FUEL LAMP - LAMP ILLUMINATED CONSTANTLY - FUEL DOES NOT DRAIN WHEN FUEL DRAIN VALVE IS OPENED - VEHICLES WITH 7.3L DI TURBO - SERVICE TIP ^ FUEL - FUEL DOES NOT DRAIN OR DRAINS SLOWLY WHEN FUEL DRAIN VALVE IS OPENED - WATER-IN-FUEL LAMP ON - VEHICLES WITH 7.3L DI TURBO-SERVICE TIP FORD: 1994-1996 F SUPER DUTY, F-250, F-350 1995-1996 ECONOLINE Article 95-25-12 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The water-in-fuel lamp may stay on and the fuel may be slow to drain or not drain at all when the fuel drain valve is opened. This may be due to internal pressure within the filter housing. ACTION Refer to the following Service Procedure to relieve pressure from the fuel system and allow the fuel to be drained from the housing. SERVICE PROCEDURE 1. Follow the procedure in the 1996 Service Manual for Fuel Filter, Fuel Heater, Water Separator and Draining. 2. If the fuel is slow draining or does not drain at all, use a screwdriver or equivalent to open the filter lid one (1) turn to vent the housing and allow the fuel to drain. 3. After draining the water separator, make sure the lid is retightened and the valve is fully closed and secure. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-25-12 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel/Water Separator: > 03-21-8 > Oct > 03 > Fuel System - Water in Fuel Lamp Illuminated Constantly Fuel/Water Separator: All Technical Service Bulletins Fuel System - Water in Fuel Lamp Illuminated Constantly Article No. 03-21-8 10/06/03 ^ WATER IN FUEL LAMP - LAMP ILLUMINATED CONSTANTLY - FUEL DOES NOT DRAIN WHEN FUEL DRAIN VALVE IS OPENED - VEHICLES WITH 7.3L DI TURBO - SERVICE TIP ^ FUEL - FUEL DOES NOT DRAIN OR DRAINS SLOWLY WHEN FUEL DRAIN VALVE IS OPENED - WATER-IN-FUEL LAMP ON - VEHICLES WITH 7.3L DI TURBO-SERVICE TIP FORD: 1994-1996 F SUPER DUTY, F-250, F-350 1995-1996 ECONOLINE Article 95-25-12 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The water-in-fuel lamp may stay on and the fuel may be slow to drain or not drain at all when the fuel drain valve is opened. This may be due to internal pressure within the filter housing. ACTION Refer to the following Service Procedure to relieve pressure from the fuel system and allow the fuel to be drained from the housing. SERVICE PROCEDURE 1. Follow the procedure in the 1996 Service Manual for Fuel Filter, Fuel Heater, Water Separator and Draining. 2. If the fuel is slow draining or does not drain at all, use a screwdriver or equivalent to open the filter lid one (1) turn to vent the housing and allow the fuel to drain. 3. After draining the water separator, make sure the lid is retightened and the valve is fully closed and secure. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-25-12 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > Page 3837 Fuel/Water Separator: Locations Fuel Filter / Water Separator The water separator is part of the fuel filter assembly mounted on top of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > Page 3838 Fuel/Water Separator: Description and Operation Water should be drained from the engine-mounted fuel/water separator whenever the warning light comes on or every 8,000 km (5,000 miles). More frequent drain intervals may be required depending on fuel quality and vehicle usage. NOTE: Dispose of drainage waste properly in accordance with all federal, state, and local requirements. The instrument panel warning lamp (WATER IN FUEL) will glow when approximately 0.1 liter (0.1 quart) of water has accumulated in the sedimenter. When the warning lamp glows, shut off the engine as soon as safely possible. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Draining Fuel/Water Separator: Service and Repair Draining DRAINING 1. Stop the vehicle and shut OFF the engine. NOTE: To avoid engine stall-out caused by air entering the fuel system, do not drain fuel/water separator while the engine is running. 2. Place an appropriate container under the fuel filter/heater/water separator drain tube to collect the drained fluid. The drain tube is attached to the manual drain valve at the base of the water separator drain bowl. 3. Manually open the drain valve by rotating it away from the fuel filter. NOTE: Allow drain valve to remain open approximately 15 seconds or until clear (water-free) diesel fuel flows from the drain tube. 4. Close the drain tube by rotating manual valve back toward the fuel filter. WARNING: After draining water separator, make sure that the drain valve is fully closed and secure. 5. Restart the engine and check WATER IN FUEL lamp. The lamp should not glow. If it continues to glow have the fuel system checked and repaired. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Draining > Page 3841 Fuel/Water Separator: Service and Repair Removal and Installation REMOVAL 1. Remove air cleaner assembly and resonator. 2. Remove turbocharger. 3. Remove air inlet crossover manifold. 4. Place a suitable container at the end of the drain hose to catch the fuel and open filter drain. 5. Remove two (2) capscrews securing fuel filter base to crankcase. 6. Remove water drain hose from fuel filter assembly. 7. Remove fuel outlet hose, located between fuel pump and filter housing. 8. Remove fuel return hose from fuel pressure regulating valve. 9. Remove two (2) fuel supply hoses connecting regulator block to cylinder head fuel rails. 10. Loosen clamp at fuel pump end on hose connecting fuel filter to inlet of high pressure stage of fuel pump. 11. Unclip wiring harness from right side of filter housing. 12. Disconnect electrical connectors from Water In Fuel (WIF) sensor and fuel heater. 13. Remove fuel filter. 14. Using a screwdriver or bar, remove fuel filter cap. Fuel filter element will come out with cap. 15. Remove and discard bevel gasket. Carefully clean mating surfaces. 16. Press in on fuel filter element locking tabs to separate element from cap. INSTALLATION 1. Install filter element to cap. 2. Install new bevel gasket. 3. Install fuel filter and cap. 4. Connect electrical connectors to WIF sensor and fuel heater. 5. Clip wiring harness to right side of filter housing. 6. Tighten clamp at fuel pump end on hose connecting fuel filter to inlet of high pressure stage of fuel pump. 7. Install two (2) fuel supply hoses connecting regulator block to cylinder head fuel rails. 8. Install fuel return hose to fuel pressure regulating valve. 9. Install fuel outlet hose, located between fuel pump and filter housing. 10. Install water drain hose to fuel filter assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Draining > Page 3842 11. Install two (2) capscrews securing fuel filter base to crankcase. 12. Install air inlet crossover manifold. 13. Install turbocharger. 14. Install air cleaner assembly and resonator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > High Pressure Oil Pump Reservoir > Component Information > Locations High Pressure Oil Pump Reservoir: Locations Pump Reservoir The oil reservoir for the high pressure pump is located on top of the engine front cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > High Pressure Oil Pump Reservoir > Component Information > Locations > Page 3847 High Pressure Oil Pump Reservoir: Description and Operation Pump Reservoir PURPOSE The oil reservoir supplies a constant supply of oil to the high pressure pump. CONSTRUCTION The reservoir is an aluminum housing attached to the top of the engine front cover. There is an inspection plug in the top of the reservoir that allows checking of the oil level. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > High Pressure Oil Pump Reservoir > Component Information > Locations > Page 3848 High Pressure Oil Pump Reservoir: Service and Repair REMOVAL 1. Remove air cleaner housing assembly. 2. Remove air inlet duct. 3. Remove hoses from pump housing. 4. Remove the oil from the high pressure oil pump reservoir using Rotunda Vacuum Pump 021-00037 or equivalent. 5. Remove the cover plate and bolts at the crankcase front cover. 6. Remove the oil pump drive sprocket bolt and washer. 7. Remove the high pressure oil pump. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > High Pressure Oil Pump Reservoir > Component Information > Locations > Page 3849 8. Remove the high pressure oil pump reservoir retaining nut and bolts and position wiring harness aside. 9. Remove the reservoir and disconnect the wire connectors from the sensors at the top and back of the reservoir. 10. Remove the high pressure oil pump drive gear. 11. Inspect gear for damage. Service as required. 12. Clean mating surfaces of crankcase front cover, cover plate, and reservoir. INSTALLATION 1. Install the high pressure oil pump drive sprocket into the crankcase front cover. 2. Install the high pressure oil pump. 3. Install the oil pump drive sprocket, bolt, and washer. Tighten bolt to 129 Nm (95 ft lb). NOTE: Make sure the oil pump drive sprocket is fully seated on the shaft of the oil pump before installing the bolt and washer or sprocket may not seat properly. The end of high pressure oil pump shaft should be flush with the front face of the oil pump drive sprocket. 4. Check oil pump drive sprocket backlash as follows: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > High Pressure Oil Pump Reservoir > Component Information > Locations > Page 3850 a. Mount Dial Indicator Bracketry D78P-4201-F and Dial Indicator D78P-4201-G or equivalent. b. Zero the dial indicator. c. Place dial indicator tip on drive sprocket tooth. d. Move drive sprocket by hand and record reading. e. If backlash reading exceeds 0.140-0.256 mm (0.0055-0.0101 in.), replace drive sprocket. 5. Apply RTV sealer to crankcase front cover and install cover plate and retaining bolts. 6. Install new gasket, sealant, and reservoir. 7. Install the oil reservoir retaining bolts. 8. Connect the sensors and harness clips. 9. Refill oil reservoir with clean engine oil. 10. Install air inlet duct. 11. Install air cleaner housing assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Mechanical Specifications Injector Control Pressure Regulator: Mechanical Specifications Injector Control Pressure Regulator 47 Nm Injection Control Pressure Solenoid Nut 6 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Mechanical Specifications > Page 3855 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Page 3856 Injector Control Pressure Regulator: Locations Pump And Regulator Sensor And Actuator Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Page 3857 The injection control pressure regulator is mounted in the high pressure oil pump on the upper front of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Page 3858 Injector Control Pressure Regulator: Description and Operation INJECTION PRESSURE REGULATOR (IPR) Injection Pressure Regulator The Injection Pressure Regulator (IPR) is a variable-position valve that controls injection control pressure. Battery voltage is supplied to the injection pressure regulator when the ignition switch is in the ON position. Valve position is controlled by switching the output signal circuit to ground inside the Powertrain Control Module (PCM). Injection pressure is controlled by the powertrain control module based on inputs from intake air temperature, engine oil temperature, manifold and barometric pressure, and pedal position. Fuel injection pressure is controlled by the injection control pressure (ICP) system.The ICP system consists of the following: ^ injection control pressure (ICP) sensor (located in the cylinder head oil gallery) ^ Injection Pressure Regulator (IPR) located in the high-pressure oil pump ^ Powertrain Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Page 3859 Injector Control Pressure Regulator: Testing and Inspection Technician High Pressure Pump Guide For the 7.3 Power Stroke Engine Pump Leak Repair Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Page 3860 High pressure pumps with oil leaks at the fittings for the high pressure lines and the lugs at the rear can be repaired in the field using the following Ford part number 2C3Z-9G804-AA kit per TSB 03-17-01. This kit contains 3 o-rings, sealant, instructions on how to clean and seal the fittings. Torque specs. for the fittings are also included. Note: Threads must be cleaned, sealant applied to the first 3 threads ad the fittings and plug tightened to proper specs. Pump Operation The IPR acts to increase ICP by restricting the path to drain. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Page 3861 The PCM attempts to increase ICP by raising the IPR%. Note: As a general rule 7.3 Power stroke engines require 500 psi ICP (1.0 volts ICPv) minimum to start. 1.) ICP System Diagnostics P1211 sets if ICP is 410 psi above or 280 psi below desired pressure for 7.5 seconds. P1212 sets if 725 psi of ICP is not detected in 6 to 15 seconds of cranking. P1280 code is for ICP circuit low (often open circuits). Typical issues include, corrosion, spread pins, or improperly crimped terminals at the ICP sensor harness connector. If a P1280 is set, the PCM will display a default value of 725 psi at idle. To verify open circuit concern use ICPv. ICP KOEO signal voltage should be between .16 to .28 volts. 2.) No Start Diagnostics IPR% goes high with no or low ICP. A leak exists in the system - P1211 or 1212 may be present. Use test plugs tool # D94T 6600 A for 94 thru 98 MY. Use test plugs tool # 303-627 & 303-628 (kit # T99T-1000-E) for 99 my and newer with quick connect. - Block off right bank (passenger side). - Attempt to start. - Start indicates leak in right bank. - Reconnect hose to right bank. - Remove right side valve cover. - Unplug injector connectors at both valve covers. - Crank the engine. - Observe spill out of the injector and top of injector bore for oil leakage. (no oil should be coming out from the spill spouts or around the injector.) -Replace injector if oil leaks from spill spout or o-ring if leak is from injector bore. If no start - leak/loss may not be right head, but ICP still low. - Block off left bank and move ICP into adapter. - Attempt to start. - Start indicates leak in left bank. - Reconnect hose to left bank and install ICP into left head. - Remove left side valve cover. - Unplug injector connectors at both valve covers. - Crank engine. - Observe spill spout of the injector and top of injector bore for oil leakage. (No oil should be coming out from the spill spout or around the injector.) -Replace injector if oil leaks from spill spout or o-ring if leak is from injector bore. If not start / low ICP on both previous tests - Block off both high pressure lines. - Crank engine. - If pressure is below 1000 psi remove IPR valve and inspect o-rings. - If the IPR valve o-ring are damaged replace them with kit # F6TZ-9C977-AA and retest. - If o-ring are ok, then replace the IPR valve and retest. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Page 3862 Note: Do not replace the pump and IPR at the same time. If during any repair, the oil reservoir is allowed to drain it should be refilled before attempting to restart the vehicle. 3.) Engine Starts But Has A P1211 Code IPR% higher than expected. Stall shortly after cold start may also be a symptom. Prior to diagnosing a vehicle with a P1211, fuel pressure should verified. This indicates a smaller leak in the high pressure system. Using the same block off plugs described earlier to block off one bank and observing IPR% when engine is running on each bank at similar rpms. Higher IPR% on one bank compared to the other would indicate a leak on the higher IPR% bank. Example: Repair as needed after locating leak as described in visual inspection in previous routing. 4.) Diagnosing P1211 With IPR% Less That 8 at Idle ICP more than 4110 psi above command for at least 7.5 seconds can set a P1211 code. IPR with low duty cycle ( less than 8% @ idle) and engine running, indicates a restriction in the drain circuit. This restriction is taking the place of the IPR valve, driving the IPR duty cycle lower, with higher than expected ICP. The excess restriction will be in the reservoir, front cover, stuck IPR valve, or debris above the edge fitter. The drain path through the reservoir and front cover can be visually verified. Typically the pump or IPR must be replaced to repair this concern. Do not replace both components at the same time. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Page 3863 This often occurs after the oil pan is resealed where excess sealant is forced through the lube system (short circuit check valve) and trapped at the edge filter of the high pressure pump. 5.) Abnormal Long Crank/Stall after cold start A worn lube oil pump can negatively affect ICP system's performance in the following ways. - Cold engine, abnormal long crank to start. (Oil pressure gauge in dash moves immediately prior to start.) - Cold engine, start then stall - then long crank to restart. (Oil pressure gauge in dash moves immediately prior to start.) These symptoms are often mis-diagnosed as high pressure oil (ICP) concerns. Both symptoms may be caused by wear in lube oil pump or thick oil (poor maintenance). Pump wear causes a decrease in pump efficiency. Cold, thick oil becomes to move. Any lube oil system failure can negatively affect the performance of the ICP system. Recession greater than .003" causes long crank to start and/or stall. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Page 3864 To measure pump wear, place a straight edge across the pump housing and use a feeler gauge to measure clearance between the inner gear and the straight edge. A pump with excess gear recession will contribute to hard start issues. When replacing the pump, the directional marking ("out" or "damper") must face the vibration damper. If installed correctly there is recess that the vibration damper fits into on the inner gear. If installed incorrectly, the inner gear will cause major damage to the front cover. 6.) For Hard Start Long Crank or No Start Where The Injector Will Not Buzz Loudly ( Has Background Buzz Only ) When Cold Some engines have a no start/or long crank to start and the injector have a low background buzz, not a strong normal buzz. After performing the buzz test multiple times the injector may start to buzz and the engine may start and run fine the rest of the day until the next cold start. Typically, we find that this is a high mileage vehicle with poor maintenance as far as oil changes are concerned. What is occuring is that the poppet inside the injector is not able to move freely because of the thick old oil. If an oil change is performed after driving the vehicle and then driven again with new oil the next cold start the engine may improve. Note: This concern is related to poor maintenance and extended the oil change intervals. If poor maintenance is the cause, then all 8 injectors will be affected. The audible sound heard while performing an injector buzz test is the poppet stopping at the upper and lower seat during actuation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Page 3865 Injector Control Pressure Regulator: Service and Repair INJECTION CONTROL PRESSURE (ICP) REGULATOR Removal 1. Remove the fuel/water separator, refer to See: Fuel/Water Separator/Service and Repair 2. Remove the plug from the high pressure oil pump reservoir. Remove the oil from the high pressure oil pump reservoir using Rotunda Vacuum Tester (014-R-1058) or equivalent. 3. Disconnect wire connector from injection control pressure solenoid. 4. Remove nut securing injection control pressure solenoid to injection pressure regulator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Page 3866 5. Remove injection control pressure solenoid. 6. Remove fuel pressure regulator from high pressure oil pump. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Pressure Oil Pump > Injector Control Pressure Regulator > Component Information > Specifications > Page 3867 Installation 1. Follow removal procedures in reverse order. 2. Tighten injection pressure regulator to 47 Nm (35 lb-ft). 3. Tighten injection control pressure solenoid nut to 6 Nm (53 lb-in). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Turbocharger Air Intake Tube Intake Air Duct: Service and Repair Turbocharger Air Intake Tube Air Intake Tube REMOVAL 1. Loosen clamp and disconnect engine air cleaner duct tube adapter from air intake tube. 2. Loosen clamp securing crankcase breather hose to crankcase breather assembly. 3. Remove bolts securing air intake tube to air inlet bracket. 4. Disconnect crankcase breather hose from crankcase breather assembly. 5. Loosen clamp and disconnect air intake tube from air intake hose and remove air intake tube. INSTALLATION 1. Connect air intake hose to air intake tube. 2. Connect crankcase breather hose to crankcase breather assembly. 3. Position air intake tube to air intake tube support bracket and install retaining bolts. Tighten bolts securely. 4. Connect engine air cleaner duct tube adapter and clamp to air intake tube. Tighten clamp securely. 5. Tighten air intake hose clamp and crankcase breather hose clamp securely. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Turbocharger Air Intake Tube > Page 3872 Intake Air Duct: Service and Repair Turbocharger Air Intake Hose Air Intake Tube REMOVAL AND INSTALLATION 1. Loosen clamps securing air intake hose to compressor housing and air intake tube. 2. Remove air intake hose and clamps. 3. Install air intake hose and clamps. Tighten clamps securely. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Control Unit: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3880 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3881 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3882 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 3884 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Engine Control - Poor Acceleration Response Accelerator Pedal Position Sensor: Technical Service Bulletins Engine Control - Poor Acceleration Response Article No. 03-21-6 10/06/03 DRIVEABILITY - ACCELERATOR PEDAL - LACK OF ACCELERATOR CONTROL WHEN MOVING FROM IDLE POSITION - POOR OR NO ENGINE RESPONSE - 7.3L DIT FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 95-10-10 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE A lack of accelerator control when moving off of the idle position may occur on some vehicles. The vehicle's engine will be at idle RPM only. This may be caused by the Idle Validation Switch (IVS) contacts not properly closing due to interference of contacts with the switch housing. ACTION Remove and install a revised accelerator pedal assembly which includes IVS. Refer to the appropriate year 7.3L Turbo Diesel Service Manual Supplement, Pages 10-02-2 and 10-02-3, for service procedures. NOTE THE IVS DATE OF MANUFACTURE IS STAMPED NEAR ITS CONNECTOR MATING SURFACE. THE DATE CODE READS AS FOLLOWS: TWO (2) DIGITS FOR CALENDAR YEAR, FOLLOWED BY TWO (2) DIGITS FOR WEEK OF CALENDAR YEAR WHEN MANUFACTURED. FOR EXAMPLE: 9503 INDICATES SWITCH MADE THE THIRD WEEK OF 1995. NOTE ALL SWITCHES WITH A DATE CODE OF 9510 AND LATER HAVE THE CORRECTED SWITCH HOUSING. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-10-10 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 3890 Accelerator Pedal Position Sensor: Specifications Accelerator Pedal Position Sensor 22-28 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Technical Service Bulletins > Page 3891 Accelerator Pedal Position Sensor: Locations Full Body View (Part 3 Of 3) The Accelerator Pedal Position Sensor is located behind LH side of instrument panel, above accelerator pedal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor: Description and Operation Accelerator Position (AP) Sensor Accelerator Pedal Position Sensor The Accelerator Pedal (AP) position sensor is a potentiometer that provides a signal to the Powertrain Control Module (PCM) proportional to the accelerator pedal position. The AP position sensor connects to the accelerator pedal shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Accelerator Position (AP) Sensor > Page 3894 Accelerator Pedal Position Sensor: Description and Operation Idle Validation Switch The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 3895 Accelerator Pedal Position Sensor: Adjustments The Accelerator Pedal (AP) position sensor cannot be adjusted. If service is required, replace accelerator pedal and shaft. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Page 3896 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor CAUTION: The accelerator pedal assembly is a calibrated unit and must be handled with care. REMOVAL 1. Disconnect the electrical connectors from the Idle Validation Switch (IVS) and the Accelerator Pedal Position (AP) sensor. 2. remove the bolts holding the accelerator pedal and shaft to the instrument panel, 3. Remove the accelerator pedal and sensor assembly from the instrument panel. INSTALLATION 1. Position accelerator pedal and sensor assembly to instrument panel and install lower nut hand tight. 2. Install and tighten accelerator pedal and sensor assembly nuts to 22-28 Nm (17-20 ft lb). 3. Connect the electrical connectors to the IVS and AP sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow Sensor: Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Mass Air Flow Sensor - Assembly Replacement > Page 3901 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Filter Restriction Sensor > Component Information > Description and Operation Fuel Filter Restriction Sensor: Description and Operation The 7.3L diesel engine is equipped with a fuel filter restriction sensor. A restriction indicator light is provided on the instrument panel (04320) to alert the operator. If the restriction indicator light goes on during normal operation, the fuel filter should be changed as soon as practical. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Injection Control Pressure Sensor (ICP) <--> [Fuel Pressure Sensor/Switch] > Component Information > Locations Injection Control Pressure Sensor (ICP): Locations Sensor And Actuator Locations The Injection Control Pressure (ICP) is located in the cylinder head oil gallery. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Injection Control Pressure Sensor (ICP) <--> [Fuel Pressure Sensor/Switch] > Component Information > Locations > Page 3908 Injection Control Pressure Sensor (ICP): Description and Operation Injection Control Pressure Sensor The Injection Control Pressure (ICP) sensor is a variable capacitance sensor that, when supplied with a 5-volt reference signal from the Powertrain Control Module (PCM), produces a linear analog voltage signal that indicates oil pressure. The ICP sensor provides a feedback signal to indicate high pressure oil so that the PCM can command the correct injector timing, pulse width and injection control pressure for proper fuel delivery at all speed and load conditions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Injection Control Pressure Sensor (ICP) <--> [Fuel Pressure Sensor/Switch] > Component Information > Locations > Page 3909 Injection Control Pressure Sensor (ICP): Service and Repair Injection Control Pressure Sensor REMOVAL 1. Disconnect Injection Control Pressure (ICP) sensor electrical connector. 2. Remove ICP sensor. INSTALLATION 1. Install ICP sensor. 2. Connect sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations Behind Instrument Panel Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations > Page 3913 Throttle Full Close Switch: Description and Operation The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations > Page 3914 Throttle Full Close Switch: Service and Repair Removal 1. Disconnect the electrical connectors from the idle validation switch and the accelerator pedal position sensor. 2. Remove the nuts holding the accelerator pedal and sensor assembly to the instrument panel. 3. Remove the accelerator pedal and sensor assembly from the instrument panel. Installation 1. Position accelerator pedal and sensor assembly to instrument panel and install accelerator pedal and sensor assembly lower nut hand tight. 2. Install and tighten the accelerator pedal and sensor assembly nuts to 21-29 nm (15-21 lb-ft). 3. Connect the electrical connectors to the idle validation switch and the accelerator pedal position sensor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations > Page 3915 Accelerator Pedal Sensors Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations Behind Instrument Panel Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations > Page 3919 Throttle Full Close Switch: Description and Operation The Idle Validation Switch (IVS) provides the Powertrain Control Module (PCM) with a redundant signal to verify when the accelerator pedal and shaft is in the idle position. Any detected malfunction of the IVS will illuminate the CHECK ENGINE light and the engine will operate at low idle only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations > Page 3920 Throttle Full Close Switch: Service and Repair Removal 1. Disconnect the electrical connectors from the idle validation switch and the accelerator pedal position sensor. 2. Remove the nuts holding the accelerator pedal and sensor assembly to the instrument panel. 3. Remove the accelerator pedal and sensor assembly from the instrument panel. Installation 1. Position accelerator pedal and sensor assembly to instrument panel and install accelerator pedal and sensor assembly lower nut hand tight. 2. Install and tighten the accelerator pedal and sensor assembly nuts to 21-29 nm (15-21 lb-ft). 3. Connect the electrical connectors to the idle validation switch and the accelerator pedal position sensor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Locations > Page 3921 Accelerator Pedal Sensors Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Exhaust Back Pressure Control Valve <--> [Exhaust Control Valve, Turbocharger] > Component Information > Specifications Exhaust Back Pressure Control Valve: Specifications Exhaust Back Pressure Valve Exhaust Back Pressure Valve Exhaust Back Pressure Control Valve Bolt 7-9 Nm Exhaust Back Pressure Control Valve Preload 10.5-16.5 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Exhaust Back Pressure Control Valve <--> [Exhaust Control Valve, Turbocharger] > Component Information > Specifications > Page 3926 Exhaust Back Pressure Control Valve: Adjustments PRELOAD Adjust actuator rod length to obtain 10 lbs. preload as measured using Spring Scale T74P-3504-Y. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Exhaust Back Pressure Control Valve <--> [Exhaust Control Valve, Turbocharger] > Component Information > Specifications > Page 3927 Exhaust Back Pressure Control Valve: Service and Repair Exhaust Back Pressure Sensor REMOVAL 1. Disconnect exhaust back pressure sensor electrical connector. 2. Remove exhaust back pressure sensor. INSTALLATION 1. Install exhaust back pressure sensor. 2. Connect sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Air Intake Hose > Component Information > Service and Repair Turbocharger Air Intake Hose: Service and Repair REMOVAL 1. Loosen clamps securing air intake hose to compressor housing and air intake tube. 2. Remove air intake hose and clamps. INSTALLATION 1. Install air intake hose to compressor housing and air intake tube. 2. Install air intake clamps. 3. Tighten clamps securely. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Air Intake Tube > Component Information > Service and Repair Turbocharger Air Intake Tube: Service and Repair REMOVAL 1. Loosen clamp and disconnect engine air cleaner duct tube adapter from air intake tube. 2. Loosen clamp securing crankcase breather hose to crankcase breather assembly. 3. Remove bolts securing air intake tube to air inlet bracket. 4. Disconnect crankcase breather hose from crankcase breather assembly. 5. Loosen clamp and disconnect air intake tube from air intake hose and remove air intake tube. INSTALLATION 1. Connect air intake hose to air intake tube. 2. Connect crankcase breather hose to crankcase breather assembly. 3. Position air intake tube to air intake tube support bracket and install retaining bolts. Tighten bolts securely. 4. Connect engine air cleaner duct tube adapter and clamp to air intake tube. Tighten clamp securely. 5. Tighten air intake hose clamp and crankcase breather hose clamp securely. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Exhaust Inlet Adapter > Component Information > Service and Repair Turbocharger Exhaust Inlet Adapter: Service and Repair REMOVAL 1. Raise vehicle. 2. Loosen nuts and bolts securing right and left turbocharger exhaust inlet pipes to exhaust manifolds. 3. Lower vehicle. 4. Remove interior engine cover. 5. Remove bolts securing right and left inlet pipes to turbocharger exhaust inlet adapter. 6. Remove bolts securing exhaust inlet adapter to turbocharger. 7. Remove turbocharger exhaust inlet adapter and gasket. 8. Clean gasket sealing surfaces. INSTALLATION 1. Using a new gasket, position exhaust inlet adapter to turbocharger. Tighten bolts to 49 Nm (36 ft lb). 2. Position right and left exhaust inlet pipes to exhaust inlet adapter. Tighten bolts to 49 Nm (36 ft lb). 3. Install interior engine cover. 4. Raise vehicle. 5. Tighten nuts and bolts securing right and left exhaust inlet pipes to exhaust manifolds to 49 Nm (36 ft lb). 6. Lower vehicle. 7. Start engine and check for exhaust leaks. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Wastegate > Component Information > Description and Operation Wastegate: Description and Operation The Garrett TP-38 turbocharger used in this application does not have a wastegate. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order: 1-2-7-3-4-5-6-8 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: Customer Interest Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 3952 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 3958 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3959 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located at the front of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3960 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor is a Hall effect sensor that generates a digital frequency while windows in a target wheel pass through its magnetic field. The frequency of the windows passing by the sensor, as well as the width of selected windows, allows the Powertrain Control Module (PCM) to detect engine speed and position. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3961 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect Camshaft Position (CMP) sensor electrical connector. 2. Remove bolt and CMP sensor. INSTALLATION 1. Install CMP sensor and bolt. 2. Connect CMP sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement Technical Service Bulletin # 94E52 Date: 950201 Recall - Ignition Control Module Inspection/Replacement 94E52 EMISSIONS RECALL Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Dealer Letter Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Customer Notification Letter Attachment I - Administrative Instructions Administrative Instructions OASIS You must use OASIS to determine if a truck is eligible for this or another recall. Note Correct all affected dealer stock trucks before delivery. Promptly Correct Affected trucks on the enclosed list and other eligible trucks on hand or brought to your dealership. Dealer Owner Contact Immediately contact any owner of an eligible truck you know of whose name is not on the list. Give the owner a copy of the Owner Letter. Region Contact Advise FCSD regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Parts and Service Zone Manager about recall concerns. Claims Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use a Form 1863 or authorized alternative claim form as an internal repair order to support your DWE entry. Please read Section 6.3 of your Warranty and Policy Manual. This section contains claim processing information including related damage/refunds and refunds. Attachment II - Labor and Parts Information Labor Allowance Inspect the Ignition Control (IC) Module for Build Date and, if necessary, Replace the Module. Obtain, Prepare and Attach an Authorized Modifications Label. Provided California Owners With "Emissions Recall - Proof of Correction" Certificates. Claim Procedure For Dealers Not On ACES II Pilot INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 3970 F-Series 0.2 Hrs. Insert in Box "A" on Form 1864 Econoline 0.4 Hrs. Insert in Box "A" on Form 1864 INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Insert in Box "B" on Form 1864 Econoline 0.5 Hrs. Insert in Box "B" on Form 1864 Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Claim Procedure for Dealers on ACES II Pilot Submit using DWE INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.2 Hrs. Labor Operation - 94E52A Econoline 0.4 Hrs. Labor Operation - 94E52A 0.1 Hrs. Misc. Expense Code "ADMIN" INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Labor Operation - 94E52B Econoline 0.5 Hrs. Labor Operation - 94E52B 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. Part Number Description F1PZ-12A297-A Module, Ignition Control (IC) For the latest part price, call or check ^ Order Processing Center ^ an updated Master Price Book ^ DOESII Excess Stock Return Excess stock returned for credit must have been purchased form Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ignition Control (IC) Module Inspection And Replacement Affected Vehicles: 1995 Model E and F-Series Trucks as follows: Kentucky Truck Plant 11/23 Thru 28, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 3971 Lorain Assembly 11/22 Thru 28, 1994 Norfolk Assembly 11/22 Thru 29, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 3972 1. Locate ignition control module under hood. On F-Series models, it is located on the left inner fender panel near the hood hinge. See Figure 1. On E-Series models, it is located behind the battery on the dash panel. See Figure 2. 2. On Econoline models only, disconnect and position battery out of the way. 3. Remove two screws retaining ignition control module heat-sink assembly to left fender apron. 4. Disconnect harness connector from ignition control module. 5. Inspect date code on module. If the date code is 4L18B, the module must be replaced. See Figure 3 for date code location. Continue on to next step. If not, go to step 9. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 3973 6. Remove two screws retaining ignition control module to heat-sink and remove ignition control module. 7. Coat metal baseplate of the replacement ignition control module uniformly with silicone compound, approximately .0179 mm (1/31-inch) thick. Use Silicone Dielectric Compound WA-10 D7AZ-19A331-A (ESE-M1C171-A) or equivalent. 8. Position ignition control module onto heat-sink and tighten two retaining screws to 1.7-4.0 N-m (15-35 in-lb). 9. Install ignition control module heat-sink assembly useing two retaining screws, and tighten to 9-14 N-m (80-124 in-lb). 10. Connect engine control sensor wiring to the ignition control module. 11. On Econoline models only, reposition and connect battery. Start engine, verify operation. Authorized Modifications Labels And California "Emissions Recall-Proof of Corrections" Certificates ^ Obtain, prepare and attach an Authorized Modifications Label (available at no-charge {package of 25 with overlay} as part number FCS-8262 or DOES II). Write on the label "IC Module Inspected/Replaced", authority, Emissions Recall 94E52", your P&A; Code and date of repair as shown below. ^ Provide California owners with "Emissions Recall-Proof of Correction " Certificates. Authorized Modifications Decal Dealer Letter RECALL NUMBER 94E52 Date: Feb., 1995 PARTS AVAILABILITY At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers At PDC By: Now Date in Owner Letter: March, 1995 To: All Dealers Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 3974 Subject: Emissions Recall 94E52 - Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Affected Vehicles Approximately 4,500 1995-model E & F-Series trucks manufactured at the Kentucky Truck Plant November 23 through 28, 1994, the Lorain Assembly Plant from November 22, through 28, 1994, and the Norfolk Assembly Plant from November 22, through 29, 1994. Reasons For Recall Some of these trucks have been built and shipped with ignition control (IC) modules which may fail and cause an engine no-start condition. Service Action The IC module will be inspected for build date and, if necessary, will be replaced. Attachments Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Owner Letter March, 1995 Serial Number: 12345678901234567 94E52 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 94E52) certain 1995-Model Econoline and F-Series Trucks. Your truck may have been manufactured with an ignition control module that may fail and cause an engine no-start condition. What The Dealer Will Do At no cost to you, your dealer will inspect the ignition control module on your truck and, if necessary, replace the module. If you do not have this service done, your Emissions Warranty may be reduced. How Long Will It Take? The time needed to repair your truck is about one-half hour. However, due to service scheduling times, your dealer may need your truck one full working day. Call Your Dealer Call your Dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When your bring your truck in, present this letter to the dealer. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address or Sold the Truck? If you have, please fill out the enclosed prepaid postcard and mail it to us. If the service for this recall is not provided promptly and without charge, talk to the dealer service manager. You may also contact the Ford Customer Assistance Center at 300 Renaissance Center, P.O. Box 43360, Detroit, MI, 48243. Please have your truck serviced promptly to maintain full Emissions warranty coverage. We regret the inconvenience this recall may cause you. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Exhaust Back Pressure Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 3978 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 9617 > Jan > 96 > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement Technical Service Bulletin # 94E52 Date: 950201 Recall - Ignition Control Module Inspection/Replacement 94E52 EMISSIONS RECALL Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Dealer Letter Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Customer Notification Letter Attachment I - Administrative Instructions Administrative Instructions OASIS You must use OASIS to determine if a truck is eligible for this or another recall. Note Correct all affected dealer stock trucks before delivery. Promptly Correct Affected trucks on the enclosed list and other eligible trucks on hand or brought to your dealership. Dealer Owner Contact Immediately contact any owner of an eligible truck you know of whose name is not on the list. Give the owner a copy of the Owner Letter. Region Contact Advise FCSD regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Parts and Service Zone Manager about recall concerns. Claims Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use a Form 1863 or authorized alternative claim form as an internal repair order to support your DWE entry. Please read Section 6.3 of your Warranty and Policy Manual. This section contains claim processing information including related damage/refunds and refunds. Attachment II - Labor and Parts Information Labor Allowance Inspect the Ignition Control (IC) Module for Build Date and, if necessary, Replace the Module. Obtain, Prepare and Attach an Authorized Modifications Label. Provided California Owners With "Emissions Recall - Proof of Correction" Certificates. Claim Procedure For Dealers Not On ACES II Pilot INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 9617 > Jan > 96 > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 3988 F-Series 0.2 Hrs. Insert in Box "A" on Form 1864 Econoline 0.4 Hrs. Insert in Box "A" on Form 1864 INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Insert in Box "B" on Form 1864 Econoline 0.5 Hrs. Insert in Box "B" on Form 1864 Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Claim Procedure for Dealers on ACES II Pilot Submit using DWE INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.2 Hrs. Labor Operation - 94E52A Econoline 0.4 Hrs. Labor Operation - 94E52A 0.1 Hrs. Misc. Expense Code "ADMIN" INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Labor Operation - 94E52B Econoline 0.5 Hrs. Labor Operation - 94E52B 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. Part Number Description F1PZ-12A297-A Module, Ignition Control (IC) For the latest part price, call or check ^ Order Processing Center ^ an updated Master Price Book ^ DOESII Excess Stock Return Excess stock returned for credit must have been purchased form Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ignition Control (IC) Module Inspection And Replacement Affected Vehicles: 1995 Model E and F-Series Trucks as follows: Kentucky Truck Plant 11/23 Thru 28, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 9617 > Jan > 96 > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 3989 Lorain Assembly 11/22 Thru 28, 1994 Norfolk Assembly 11/22 Thru 29, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 9617 > Jan > 96 > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 3990 1. Locate ignition control module under hood. On F-Series models, it is located on the left inner fender panel near the hood hinge. See Figure 1. On E-Series models, it is located behind the battery on the dash panel. See Figure 2. 2. On Econoline models only, disconnect and position battery out of the way. 3. Remove two screws retaining ignition control module heat-sink assembly to left fender apron. 4. Disconnect harness connector from ignition control module. 5. Inspect date code on module. If the date code is 4L18B, the module must be replaced. See Figure 3 for date code location. Continue on to next step. If not, go to step 9. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 9617 > Jan > 96 > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 3991 6. Remove two screws retaining ignition control module to heat-sink and remove ignition control module. 7. Coat metal baseplate of the replacement ignition control module uniformly with silicone compound, approximately .0179 mm (1/31-inch) thick. Use Silicone Dielectric Compound WA-10 D7AZ-19A331-A (ESE-M1C171-A) or equivalent. 8. Position ignition control module onto heat-sink and tighten two retaining screws to 1.7-4.0 N-m (15-35 in-lb). 9. Install ignition control module heat-sink assembly useing two retaining screws, and tighten to 9-14 N-m (80-124 in-lb). 10. Connect engine control sensor wiring to the ignition control module. 11. On Econoline models only, reposition and connect battery. Start engine, verify operation. Authorized Modifications Labels And California "Emissions Recall-Proof of Corrections" Certificates ^ Obtain, prepare and attach an Authorized Modifications Label (available at no-charge {package of 25 with overlay} as part number FCS-8262 or DOES II). Write on the label "IC Module Inspected/Replaced", authority, Emissions Recall 94E52", your P&A; Code and date of repair as shown below. ^ Provide California owners with "Emissions Recall-Proof of Correction " Certificates. Authorized Modifications Decal Dealer Letter RECALL NUMBER 94E52 Date: Feb., 1995 PARTS AVAILABILITY At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers At PDC By: Now Date in Owner Letter: March, 1995 To: All Dealers Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 9617 > Jan > 96 > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 3992 Subject: Emissions Recall 94E52 - Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Affected Vehicles Approximately 4,500 1995-model E & F-Series trucks manufactured at the Kentucky Truck Plant November 23 through 28, 1994, the Lorain Assembly Plant from November 22, through 28, 1994, and the Norfolk Assembly Plant from November 22, through 29, 1994. Reasons For Recall Some of these trucks have been built and shipped with ignition control (IC) modules which may fail and cause an engine no-start condition. Service Action The IC module will be inspected for build date and, if necessary, will be replaced. Attachments Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Owner Letter March, 1995 Serial Number: 12345678901234567 94E52 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 94E52) certain 1995-Model Econoline and F-Series Trucks. Your truck may have been manufactured with an ignition control module that may fail and cause an engine no-start condition. What The Dealer Will Do At no cost to you, your dealer will inspect the ignition control module on your truck and, if necessary, replace the module. If you do not have this service done, your Emissions Warranty may be reduced. How Long Will It Take? The time needed to repair your truck is about one-half hour. However, due to service scheduling times, your dealer may need your truck one full working day. Call Your Dealer Call your Dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When your bring your truck in, present this letter to the dealer. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address or Sold the Truck? If you have, please fill out the enclosed prepaid postcard and mail it to us. If the service for this recall is not provided promptly and without charge, talk to the dealer service manager. You may also contact the Ford Customer Assistance Center at 300 Renaissance Center, P.O. Box 43360, Detroit, MI, 48243. Please have your truck serviced promptly to maintain full Emissions warranty coverage. We regret the inconvenience this recall may cause you. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement Technical Service Bulletin # 94E52 Date: 950201 Recall - Ignition Control Module Inspection/Replacement 94E52 EMISSIONS RECALL Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Dealer Letter Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Customer Notification Letter Attachment I - Administrative Instructions Administrative Instructions OASIS You must use OASIS to determine if a truck is eligible for this or another recall. Note Correct all affected dealer stock trucks before delivery. Promptly Correct Affected trucks on the enclosed list and other eligible trucks on hand or brought to your dealership. Dealer Owner Contact Immediately contact any owner of an eligible truck you know of whose name is not on the list. Give the owner a copy of the Owner Letter. Region Contact Advise FCSD regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Parts and Service Zone Manager about recall concerns. Claims Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use a Form 1863 or authorized alternative claim form as an internal repair order to support your DWE entry. Please read Section 6.3 of your Warranty and Policy Manual. This section contains claim processing information including related damage/refunds and refunds. Attachment II - Labor and Parts Information Labor Allowance Inspect the Ignition Control (IC) Module for Build Date and, if necessary, Replace the Module. Obtain, Prepare and Attach an Authorized Modifications Label. Provided California Owners With "Emissions Recall - Proof of Correction" Certificates. Claim Procedure For Dealers Not On ACES II Pilot INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 4002 F-Series 0.2 Hrs. Insert in Box "A" on Form 1864 Econoline 0.4 Hrs. Insert in Box "A" on Form 1864 INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Insert in Box "B" on Form 1864 Econoline 0.5 Hrs. Insert in Box "B" on Form 1864 Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Claim Procedure for Dealers on ACES II Pilot Submit using DWE INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.2 Hrs. Labor Operation - 94E52A Econoline 0.4 Hrs. Labor Operation - 94E52A 0.1 Hrs. Misc. Expense Code "ADMIN" INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Labor Operation - 94E52B Econoline 0.5 Hrs. Labor Operation - 94E52B 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. Part Number Description F1PZ-12A297-A Module, Ignition Control (IC) For the latest part price, call or check ^ Order Processing Center ^ an updated Master Price Book ^ DOESII Excess Stock Return Excess stock returned for credit must have been purchased form Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ignition Control (IC) Module Inspection And Replacement Affected Vehicles: 1995 Model E and F-Series Trucks as follows: Kentucky Truck Plant 11/23 Thru 28, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 4003 Lorain Assembly 11/22 Thru 28, 1994 Norfolk Assembly 11/22 Thru 29, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 4004 1. Locate ignition control module under hood. On F-Series models, it is located on the left inner fender panel near the hood hinge. See Figure 1. On E-Series models, it is located behind the battery on the dash panel. See Figure 2. 2. On Econoline models only, disconnect and position battery out of the way. 3. Remove two screws retaining ignition control module heat-sink assembly to left fender apron. 4. Disconnect harness connector from ignition control module. 5. Inspect date code on module. If the date code is 4L18B, the module must be replaced. See Figure 3 for date code location. Continue on to next step. If not, go to step 9. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 4005 6. Remove two screws retaining ignition control module to heat-sink and remove ignition control module. 7. Coat metal baseplate of the replacement ignition control module uniformly with silicone compound, approximately .0179 mm (1/31-inch) thick. Use Silicone Dielectric Compound WA-10 D7AZ-19A331-A (ESE-M1C171-A) or equivalent. 8. Position ignition control module onto heat-sink and tighten two retaining screws to 1.7-4.0 N-m (15-35 in-lb). 9. Install ignition control module heat-sink assembly useing two retaining screws, and tighten to 9-14 N-m (80-124 in-lb). 10. Connect engine control sensor wiring to the ignition control module. 11. On Econoline models only, reposition and connect battery. Start engine, verify operation. Authorized Modifications Labels And California "Emissions Recall-Proof of Corrections" Certificates ^ Obtain, prepare and attach an Authorized Modifications Label (available at no-charge {package of 25 with overlay} as part number FCS-8262 or DOES II). Write on the label "IC Module Inspected/Replaced", authority, Emissions Recall 94E52", your P&A; Code and date of repair as shown below. ^ Provide California owners with "Emissions Recall-Proof of Correction " Certificates. Authorized Modifications Decal Dealer Letter RECALL NUMBER 94E52 Date: Feb., 1995 PARTS AVAILABILITY At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers At PDC By: Now Date in Owner Letter: March, 1995 To: All Dealers Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Recalls for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 4006 Subject: Emissions Recall 94E52 - Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Affected Vehicles Approximately 4,500 1995-model E & F-Series trucks manufactured at the Kentucky Truck Plant November 23 through 28, 1994, the Lorain Assembly Plant from November 22, through 28, 1994, and the Norfolk Assembly Plant from November 22, through 29, 1994. Reasons For Recall Some of these trucks have been built and shipped with ignition control (IC) modules which may fail and cause an engine no-start condition. Service Action The IC module will be inspected for build date and, if necessary, will be replaced. Attachments Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Owner Letter March, 1995 Serial Number: 12345678901234567 94E52 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 94E52) certain 1995-Model Econoline and F-Series Trucks. Your truck may have been manufactured with an ignition control module that may fail and cause an engine no-start condition. What The Dealer Will Do At no cost to you, your dealer will inspect the ignition control module on your truck and, if necessary, replace the module. If you do not have this service done, your Emissions Warranty may be reduced. How Long Will It Take? The time needed to repair your truck is about one-half hour. However, due to service scheduling times, your dealer may need your truck one full working day. Call Your Dealer Call your Dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When your bring your truck in, present this letter to the dealer. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address or Sold the Truck? If you have, please fill out the enclosed prepaid postcard and mail it to us. If the service for this recall is not provided promptly and without charge, talk to the dealer service manager. You may also contact the Ford Customer Assistance Center at 300 Renaissance Center, P.O. Box 43360, Detroit, MI, 48243. Please have your truck serviced promptly to maintain full Emissions warranty coverage. We regret the inconvenience this recall may cause you. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement Technical Service Bulletin # 94E52 Date: 950201 Recall - Ignition Control Module Inspection/Replacement 94E52 EMISSIONS RECALL Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Dealer Letter Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Customer Notification Letter Attachment I - Administrative Instructions Administrative Instructions OASIS You must use OASIS to determine if a truck is eligible for this or another recall. Note Correct all affected dealer stock trucks before delivery. Promptly Correct Affected trucks on the enclosed list and other eligible trucks on hand or brought to your dealership. Dealer Owner Contact Immediately contact any owner of an eligible truck you know of whose name is not on the list. Give the owner a copy of the Owner Letter. Region Contact Advise FCSD regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Parts and Service Zone Manager about recall concerns. Claims Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use a Form 1863 or authorized alternative claim form as an internal repair order to support your DWE entry. Please read Section 6.3 of your Warranty and Policy Manual. This section contains claim processing information including related damage/refunds and refunds. Attachment II - Labor and Parts Information Labor Allowance Inspect the Ignition Control (IC) Module for Build Date and, if necessary, Replace the Module. Obtain, Prepare and Attach an Authorized Modifications Label. Provided California Owners With "Emissions Recall - Proof of Correction" Certificates. Claim Procedure For Dealers Not On ACES II Pilot INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 4012 F-Series 0.2 Hrs. Insert in Box "A" on Form 1864 Econoline 0.4 Hrs. Insert in Box "A" on Form 1864 INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Insert in Box "B" on Form 1864 Econoline 0.5 Hrs. Insert in Box "B" on Form 1864 Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Claim Procedure for Dealers on ACES II Pilot Submit using DWE INSPECT IC MODULE FOR BUILD DATE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.2 Hrs. Labor Operation - 94E52A Econoline 0.4 Hrs. Labor Operation - 94E52A 0.1 Hrs. Misc. Expense Code "ADMIN" INSPECT IC MODULE FOR BUILD DATE AND REPLACE MODULE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE F-Series 0.3 Hrs. Labor Operation - 94E52B Econoline 0.5 Hrs. Labor Operation - 94E52B 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. Part Number Description F1PZ-12A297-A Module, Ignition Control (IC) For the latest part price, call or check ^ Order Processing Center ^ an updated Master Price Book ^ DOESII Excess Stock Return Excess stock returned for credit must have been purchased form Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ignition Control (IC) Module Inspection And Replacement Affected Vehicles: 1995 Model E and F-Series Trucks as follows: Kentucky Truck Plant 11/23 Thru 28, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 4013 Lorain Assembly 11/22 Thru 28, 1994 Norfolk Assembly 11/22 Thru 29, 1994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 4014 1. Locate ignition control module under hood. On F-Series models, it is located on the left inner fender panel near the hood hinge. See Figure 1. On E-Series models, it is located behind the battery on the dash panel. See Figure 2. 2. On Econoline models only, disconnect and position battery out of the way. 3. Remove two screws retaining ignition control module heat-sink assembly to left fender apron. 4. Disconnect harness connector from ignition control module. 5. Inspect date code on module. If the date code is 4L18B, the module must be replaced. See Figure 3 for date code location. Continue on to next step. If not, go to step 9. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 4015 6. Remove two screws retaining ignition control module to heat-sink and remove ignition control module. 7. Coat metal baseplate of the replacement ignition control module uniformly with silicone compound, approximately .0179 mm (1/31-inch) thick. Use Silicone Dielectric Compound WA-10 D7AZ-19A331-A (ESE-M1C171-A) or equivalent. 8. Position ignition control module onto heat-sink and tighten two retaining screws to 1.7-4.0 N-m (15-35 in-lb). 9. Install ignition control module heat-sink assembly useing two retaining screws, and tighten to 9-14 N-m (80-124 in-lb). 10. Connect engine control sensor wiring to the ignition control module. 11. On Econoline models only, reposition and connect battery. Start engine, verify operation. Authorized Modifications Labels And California "Emissions Recall-Proof of Corrections" Certificates ^ Obtain, prepare and attach an Authorized Modifications Label (available at no-charge {package of 25 with overlay} as part number FCS-8262 or DOES II). Write on the label "IC Module Inspected/Replaced", authority, Emissions Recall 94E52", your P&A; Code and date of repair as shown below. ^ Provide California owners with "Emissions Recall-Proof of Correction " Certificates. Authorized Modifications Decal Dealer Letter RECALL NUMBER 94E52 Date: Feb., 1995 PARTS AVAILABILITY At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers At PDC By: Now Date in Owner Letter: March, 1995 To: All Dealers Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 94E52 > Feb > 95 > Recall - Ignition Control Module Inspection/Replacement > Page 4016 Subject: Emissions Recall 94E52 - Certain 1995 Model E & F-Series Trucks - Ignition Control (IC) Modules Affected Vehicles Approximately 4,500 1995-model E & F-Series trucks manufactured at the Kentucky Truck Plant November 23 through 28, 1994, the Lorain Assembly Plant from November 22, through 28, 1994, and the Norfolk Assembly Plant from November 22, through 29, 1994. Reasons For Recall Some of these trucks have been built and shipped with ignition control (IC) modules which may fail and cause an engine no-start condition. Service Action The IC module will be inspected for build date and, if necessary, will be replaced. Attachments Attachment I ^ Administrative Instructions Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Owner Letter March, 1995 Serial Number: 12345678901234567 94E52 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 94E52) certain 1995-Model Econoline and F-Series Trucks. Your truck may have been manufactured with an ignition control module that may fail and cause an engine no-start condition. What The Dealer Will Do At no cost to you, your dealer will inspect the ignition control module on your truck and, if necessary, replace the module. If you do not have this service done, your Emissions Warranty may be reduced. How Long Will It Take? The time needed to repair your truck is about one-half hour. However, due to service scheduling times, your dealer may need your truck one full working day. Call Your Dealer Call your Dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When your bring your truck in, present this letter to the dealer. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address or Sold the Truck? If you have, please fill out the enclosed prepaid postcard and mail it to us. If the service for this recall is not provided promptly and without charge, talk to the dealer service manager. You may also contact the Ford Customer Assistance Center at 300 Renaissance Center, P.O. Box 43360, Detroit, MI, 48243. Please have your truck serviced promptly to maintain full Emissions warranty coverage. We regret the inconvenience this recall may cause you. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: Customer Interest Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 4026 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 4032 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4033 Camshaft Position Sensor: Locations Engine View The Camshaft Position Sensor is located at the front of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4034 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor The Camshaft Position (CMP) sensor is a Hall effect sensor that generates a digital frequency while windows in a target wheel pass through its magnetic field. The frequency of the windows passing by the sensor, as well as the width of selected windows, allows the Powertrain Control Module (PCM) to detect engine speed and position. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4035 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor REMOVAL 1. Disconnect Camshaft Position (CMP) sensor electrical connector. 2. Remove bolt and CMP sensor. INSTALLATION 1. Install CMP sensor and bolt. 2. Connect CMP sensor electrical connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams Ignition Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 4039 Ignition Switch: Testing and Inspection Ignition Switch - Component Testing Procedure (Part 1 Of 2) Ignition Switch - Component Testing Procedure (Part 2 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 4040 Ignition Switch - Terminal Locations Ignition Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Specifications > Electrical Specifications Glow Plug: Electrical Specifications Glow Plugs 0.1-6.0 ohms Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Specifications > Electrical Specifications > Page 4046 Glow Plug: Mechanical Specifications Glow Plug 19 Nm Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Specifications > Page 4047 Glow Plug: Locations Glow Plug The glow plugs are mounted in the cylinder heads, under the valve cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Specifications > Page 4048 Glow Plug: Description and Operation DESCRIPTION AND OPERATION Glow Plugs The intake manifold glow plugs warm up the cylinders to improve cold engine starting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Glow Plug: Initial Inspection and Diagnostic Overview Clean and inspect the intake manifold glow plug tip for damage. Replace if damaged. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4051 Glow Plug: Component Tests and General Diagnostics 1. Disconnect glow plug/injector harness connectors from the valve cover gasket. Glow Plug Testing 2. With the pigtail installed, measure glow plug resistance to battery negative terminal. 3. A resistance measurement of 0.1 - 6 ohms indicates a good glow plug. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Service and Repair > Glow Plug Glow Plug: Service and Repair Glow Plug REMOVAL 1. Remove the valve cover. 2. Disconnect the glow plug electrical connector using a pair of pliers. WARNING: Red-striped Wires Carry 115V DC. Severe electrical shock may be received. Do not pierce. 3. Remove the intake manifold glow plug using 10 mm socket. 4. Clean and inspect the intake manifold glow plug tip for damage. Replace if damaged. INSTALLATION 1. Install the intake manifold glow plug and tighten to 19 Nm (14 ft lb). 2. Connect the glow plug electrical connector. 3. Install the valve cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Service and Repair > Glow Plug > Page 4054 Glow Plug: Service and Repair Glow Plug Wiring Harness REMOVAL WARNING: Red-striped wires carry 115 volts DC. Severe electrical shock may be received. Do not pierce. CAUTION: Do not pierce engine electrical wires or damage to the harness may occur. 1. Disconnect battery ground cable or cables if applicable to multiple battery vehicles. 2. Remove engine cover. 3. Remove valve covers. 4. Disconnect wire connectors from fuel injectors. Glow Plug Connector Removal 5. Using long needle-nose pliers, remove wire connectors from glow plugs. Do not pull on wires when disconnecting glow plug wire connectors. 6. Disconnect wire connector from valve cover gasket using care not to damage valve cover gasket. 7. Remove fuel charging wiring. INSTALLATION 1. Install fuel charging wiring. 2. Connect wire connector to valve cover gasket using care not to damage valve cover gasket. 3. Connect wire connectors to glow plugs. 4. Connect wire connectors to fuel injectors. 5. Install valve covers. 6. Install engine cover. 7. Connect battery ground cable or cables if applicable to multiple battery vehicles. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Customer Interest for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition Glow Plug Relay: Customer Interest Diesel Engine - Hard Start/No Start Condition Article No. 96-1-7 01/02/96 ^ HARD START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ NO START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ ENGINE - 7.3L DIT DIESEL - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 LIGHT TRUCK: 1994-95 F SUPER DUTY, F-25O, F-35O 1995 E-35O ISSUE: The glow plug relay may melt and result in a no start/hard start condition. This may be caused by the nuts on the glow plug relay losing their torque and increasing the resistance on the connections of the relay. ACTION: Increase the torque of the nuts on the glow plug relay and add a lockwasher. Refer to the following Service Procedure for details. NOTE: THIS PROCEDURE SHOULD BE ADHERED TO FOR ALL FUTURE GLOW PLUG REPAIRS ON 7.3L DIT DIESEL ENGINES. SERVICE PROCEDURE CAUTION: DO NOT USE A SCREWDRIVER OR SIMILAR TOOL TO PRY OFF THE TERMINAL COVER. BATTERY VOLTAGE IS PRESENT AT THE TERMINALS. 1. Disconnect the batteries. 2. Remove the glow plug relay plastic terminal cover. 3. Remove glow plug relay nuts. 4. Add zinc plated lockwashers (34791-S36) on top of the wire harness connectors below the upper nuts. CAUTION: ZINC PLATED LOCKWASHERS MUST BE USED. 5. Replace nuts and torque to 7.9 t0.6 N-m (70 +/- 5 lb-in). CAUTION: DO NOT OVERTORQUE. DAMAGE TO THE RELAY WILL RESULT. 6. With the addition of the lockwasher, the plastic terminal cover may not remain securely attached to the studs. Therefore, apply Silastic Sealer (F4AZ-19562-B) to the plastic terminal cover to make sure the cover remains secure. Replace the cover. 7. Reconnect the batteries. PART NUMBER PART NAME 34791-536 Zinc Plated Lockwasher F4AZ-19562-B Silastic Sealer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960107A Install Lockwashers And 0.4 Hr. Apply Increased Torque DEALER CODING Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Customer Interest for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition > Page 4063 CONDITION BASIC PART NO. CODE 12B533 H4 OASIS CODES: 203000, 203200, 601300, 602300, 603300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition Glow Plug Relay: All Technical Service Bulletins Diesel Engine - Hard Start/No Start Condition Article No. 96-1-7 01/02/96 ^ HARD START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ NO START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ ENGINE - 7.3L DIT DIESEL - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 LIGHT TRUCK: 1994-95 F SUPER DUTY, F-25O, F-35O 1995 E-35O ISSUE: The glow plug relay may melt and result in a no start/hard start condition. This may be caused by the nuts on the glow plug relay losing their torque and increasing the resistance on the connections of the relay. ACTION: Increase the torque of the nuts on the glow plug relay and add a lockwasher. Refer to the following Service Procedure for details. NOTE: THIS PROCEDURE SHOULD BE ADHERED TO FOR ALL FUTURE GLOW PLUG REPAIRS ON 7.3L DIT DIESEL ENGINES. SERVICE PROCEDURE CAUTION: DO NOT USE A SCREWDRIVER OR SIMILAR TOOL TO PRY OFF THE TERMINAL COVER. BATTERY VOLTAGE IS PRESENT AT THE TERMINALS. 1. Disconnect the batteries. 2. Remove the glow plug relay plastic terminal cover. 3. Remove glow plug relay nuts. 4. Add zinc plated lockwashers (34791-S36) on top of the wire harness connectors below the upper nuts. CAUTION: ZINC PLATED LOCKWASHERS MUST BE USED. 5. Replace nuts and torque to 7.9 t0.6 N-m (70 +/- 5 lb-in). CAUTION: DO NOT OVERTORQUE. DAMAGE TO THE RELAY WILL RESULT. 6. With the addition of the lockwasher, the plastic terminal cover may not remain securely attached to the studs. Therefore, apply Silastic Sealer (F4AZ-19562-B) to the plastic terminal cover to make sure the cover remains secure. Replace the cover. 7. Reconnect the batteries. PART NUMBER PART NAME 34791-536 Zinc Plated Lockwasher F4AZ-19562-B Silastic Sealer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960107A Install Lockwashers And 0.4 Hr. Apply Increased Torque DEALER CODING Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition > Page 4069 CONDITION BASIC PART NO. CODE 12B533 H4 OASIS CODES: 203000, 203200, 601300, 602300, 603300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Page 4070 Glow Plug Relay: Locations Glow Plug Relay The glow plug relay is mounted on top of the engine, behind the generator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Page 4071 Glow Plug Relay: Description and Operation DESCRIPTION The glow plug control module has a plastic base and two mounting bolts. It is operated by the Powertrain Control Module (PCM) which senses engine oil temperature, PCM voltage, and barometric pressure. OPERATION When the engine oil temperature or the barometric pressure is low, the PCM activates the glow plug control module and the intake manifold glow plugs. If the PCM voltage is too high, the PCM deactivates the glow plug control module and the intake manifold glow plugs immediately energize for a shorter duration, decreasing the modulation of the duty cycle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Page 4072 Glow Plug Relay: Service and Repair REMOVAL 1. Disconnect the batteries. 2. Remove the plastic terminal cover from the relay. CAUTION: Do not use a screwdriver or similar tool to pry off the terminal cover. Battery voltage is present at the terminals. 3. Disconnect the battery terminal connector (12 volt power wire), the glow plug relay connector, and the harness connector. 4. Remove the mounting screws and remove the relay from the engine. INSTALLATION 1. Install the relay on the engine and tighten the screws. 2. Reconnect the harness connector, relay connector, and the battery terminal connector. 3. Reinstall the plastic terminal cover. 4. Reconnect the batteries. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Customer Interest for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition Glow Plug Relay: Customer Interest Diesel Engine - Hard Start/No Start Condition Article No. 96-1-7 01/02/96 ^ HARD START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ NO START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ ENGINE - 7.3L DIT DIESEL - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 LIGHT TRUCK: 1994-95 F SUPER DUTY, F-25O, F-35O 1995 E-35O ISSUE: The glow plug relay may melt and result in a no start/hard start condition. This may be caused by the nuts on the glow plug relay losing their torque and increasing the resistance on the connections of the relay. ACTION: Increase the torque of the nuts on the glow plug relay and add a lockwasher. Refer to the following Service Procedure for details. NOTE: THIS PROCEDURE SHOULD BE ADHERED TO FOR ALL FUTURE GLOW PLUG REPAIRS ON 7.3L DIT DIESEL ENGINES. SERVICE PROCEDURE CAUTION: DO NOT USE A SCREWDRIVER OR SIMILAR TOOL TO PRY OFF THE TERMINAL COVER. BATTERY VOLTAGE IS PRESENT AT THE TERMINALS. 1. Disconnect the batteries. 2. Remove the glow plug relay plastic terminal cover. 3. Remove glow plug relay nuts. 4. Add zinc plated lockwashers (34791-S36) on top of the wire harness connectors below the upper nuts. CAUTION: ZINC PLATED LOCKWASHERS MUST BE USED. 5. Replace nuts and torque to 7.9 t0.6 N-m (70 +/- 5 lb-in). CAUTION: DO NOT OVERTORQUE. DAMAGE TO THE RELAY WILL RESULT. 6. With the addition of the lockwasher, the plastic terminal cover may not remain securely attached to the studs. Therefore, apply Silastic Sealer (F4AZ-19562-B) to the plastic terminal cover to make sure the cover remains secure. Replace the cover. 7. Reconnect the batteries. PART NUMBER PART NAME 34791-536 Zinc Plated Lockwasher F4AZ-19562-B Silastic Sealer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960107A Install Lockwashers And 0.4 Hr. Apply Increased Torque DEALER CODING Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Customer Interest for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition > Page 4082 CONDITION BASIC PART NO. CODE 12B533 H4 OASIS CODES: 203000, 203200, 601300, 602300, 603300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition Glow Plug Relay: All Technical Service Bulletins Diesel Engine - Hard Start/No Start Condition Article No. 96-1-7 01/02/96 ^ HARD START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ NO START - 7.3L DIT DIESEL ENGINE - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 ^ ENGINE - 7.3L DIT DIESEL - GLOW PLUG RELAY MELTING - VEHICLES BUILT THROUGH 12/21/94 LIGHT TRUCK: 1994-95 F SUPER DUTY, F-25O, F-35O 1995 E-35O ISSUE: The glow plug relay may melt and result in a no start/hard start condition. This may be caused by the nuts on the glow plug relay losing their torque and increasing the resistance on the connections of the relay. ACTION: Increase the torque of the nuts on the glow plug relay and add a lockwasher. Refer to the following Service Procedure for details. NOTE: THIS PROCEDURE SHOULD BE ADHERED TO FOR ALL FUTURE GLOW PLUG REPAIRS ON 7.3L DIT DIESEL ENGINES. SERVICE PROCEDURE CAUTION: DO NOT USE A SCREWDRIVER OR SIMILAR TOOL TO PRY OFF THE TERMINAL COVER. BATTERY VOLTAGE IS PRESENT AT THE TERMINALS. 1. Disconnect the batteries. 2. Remove the glow plug relay plastic terminal cover. 3. Remove glow plug relay nuts. 4. Add zinc plated lockwashers (34791-S36) on top of the wire harness connectors below the upper nuts. CAUTION: ZINC PLATED LOCKWASHERS MUST BE USED. 5. Replace nuts and torque to 7.9 t0.6 N-m (70 +/- 5 lb-in). CAUTION: DO NOT OVERTORQUE. DAMAGE TO THE RELAY WILL RESULT. 6. With the addition of the lockwasher, the plastic terminal cover may not remain securely attached to the studs. Therefore, apply Silastic Sealer (F4AZ-19562-B) to the plastic terminal cover to make sure the cover remains secure. Replace the cover. 7. Reconnect the batteries. PART NUMBER PART NAME 34791-536 Zinc Plated Lockwasher F4AZ-19562-B Silastic Sealer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960107A Install Lockwashers And 0.4 Hr. Apply Increased Torque DEALER CODING Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Glow Plug Relay: > 9617 > Jan > 96 > Diesel Engine - Hard Start/No Start Condition > Page 4088 CONDITION BASIC PART NO. CODE 12B533 H4 OASIS CODES: 203000, 203200, 601300, 602300, 603300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Page 4089 Glow Plug Relay: Locations Glow Plug Relay The glow plug relay is mounted on top of the engine, behind the generator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Page 4090 Glow Plug Relay: Description and Operation DESCRIPTION The glow plug control module has a plastic base and two mounting bolts. It is operated by the Powertrain Control Module (PCM) which senses engine oil temperature, PCM voltage, and barometric pressure. OPERATION When the engine oil temperature or the barometric pressure is low, the PCM activates the glow plug control module and the intake manifold glow plugs. If the PCM voltage is too high, the PCM deactivates the glow plug control module and the intake manifold glow plugs immediately energize for a shorter duration, decreasing the modulation of the duty cycle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Relay > Component Information > Technical Service Bulletins > Page 4091 Glow Plug Relay: Service and Repair REMOVAL 1. Disconnect the batteries. 2. Remove the plastic terminal cover from the relay. CAUTION: Do not use a screwdriver or similar tool to pry off the terminal cover. Battery voltage is present at the terminals. 3. Disconnect the battery terminal connector (12 volt power wire), the glow plug relay connector, and the harness connector. 4. Remove the mounting screws and remove the relay from the engine. INSTALLATION 1. Install the relay on the engine and tighten the screws. 2. Reconnect the harness connector, relay connector, and the battery terminal connector. 3. Reinstall the plastic terminal cover. 4. Reconnect the batteries. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Diagrams > Diagram Information and Instructions Wait To Start Light: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4096 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4097 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4098 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4099 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4100 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4101 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4102 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4103 Engine Controls Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Glow Plug System > Wait To Start Light > Component Information > Diagrams > Page 4104 Wait To Start Light: Description and Operation Glow Plug Lamp Control The Glow Plug Lamp (GPL) signal controls the WAIT TO START light located on the instrument panel. This light is used to indicate when to start the engine. The cylinders are being warmed by the glow plugs while this light is on. The Powertrain Control Module (PCM) energizes the glow plug lamp longer if the engine is very cold or if the barometric pressure is low. When the GPL signal is low, the WAIT TO START light is turned on. The glow plug lamp is controlled by the following sequence: 1. PCM lights the WAIT TO START light after a key on reset occurs. The PCM determines the glow plug lamp activation time based on engine oil temperature, barometric pressure and battery voltage. 2. PCM turns off the WAIT TO START light. The glow plug lamp is turned off when the timer counts to the number of seconds specified by the PCM. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Description and Operation Electronic Pressure Control Solenoid: Description and Operation DESCRIPTION The Electronic Pressure Control (EPC) Solenoid is a Variable Force Solenoid. The VFS-type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. OPERATION The EPC solenoid supplies Electronic Pressure Control which regulates transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and the line modulator circuits. These two pressures control the clutch application pressures. CAUTION: The electronic pressure control pressure output from the variable force solenoid is NOT adjustable. Any modification to the electronic pressure control solenoid will affect the transmission warranty. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove steering column. 2. Unclip wire terminal from shift interlock actuator. 3. Remove two screws from insert plate and shift interlock actuator. INSTALLATION 1. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Malfunction Indicator Lamp - A/T > Component Information > Description and Operation Malfunction Indicator Lamp - A/T: Description and Operation Transmission Control Indicator (TCIL) DESCRIPTION Indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation Power Control Module (PCM). Description The operation of the E4OD automatic transmission is controlled by the PCM. Many input sensors provide information to the PCM, which then controls the actuators which affect transmission operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation Brake Switch - TCC: Description and Operation Brake On/Off (BOO) Switch DESCRIPTION The Brake On/0ff switch tells the powertrain control module when the brakes are applied. The switch is closed when the brakes are applied and open when they are released. FUNCTION Disengages torque converter clutch when brake is applied. RELATED SYMPTOMS Failed on or not connected - Torque converter clutch will not engage at less than 1/3 throttle. Failed off - Torque converter clutch will not disengage when brake is applied. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Description and Operation > Accelerator Pedal (AP) Sensor Throttle Position Sensor/Switch: Description and Operation Accelerator Pedal (AP) Sensor Accelerator Pedal (AP) Sensor DESCRIPTION The Accelerator Pedal (AP) Sensor is mounted on the accelerator pedal and detects the position of the accelerator pedal. OPERATION The accelerator pedal position information is sent as a voltage signal to the PCM. The PCM uses this information to determine shift scheduling and electronic pressure control. FUNCTION If a malfunction occurs in the AP sensor circuit, the PCM will recognize that the AP signal is out of specification. The PCM will then operate the E4OD at a high line pressure to prevent transmission damage. This higher line pressure results in harsh upshifts and engagements. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Description and Operation > Accelerator Pedal (AP) Sensor > Page 4133 Throttle Position Sensor/Switch: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor Description The Throttle Position (TP) sensor is a potentiometer attached to the fuel injection pump and is operated by the throttle lever. Operation The TP sensor is incorporated to provide an electrical signal, which is proportional to the amount of fuel being delivered, as an input to the Powertrain Control Module (PCM). Based on this information, the TP sensor provides the proper shift scheduling and torque capacity. Should a malfunction occur in the TP sensor circuit, the electrical signal sent to the PCM will be recognized as erroneous. When this out-of-specification signal is detected, the PCM will operate the E4OD at a higher line pressure to protect the transmission from potential damage. This high line pressure, results in harsh upshifts and engagements. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power/Economy Mode Switch, A/T Transmission Mode Switch: Description and Operation Power/Economy Mode Switch, A/T Transmission Control Switch (TCS) DESCRIPTION The Transmission Control Switch (TCS) is a momentary contact switch which disables 4th gear operation and enables engine braking when activated. OPERATION When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM). The PCM then energizes the Transmission Control Indicator Lamp (TCIL) and the Coast Clutch Solenoid (CCS), applying the coast clutch to provide engine braking and cancels fourth gear operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power/Economy Mode Switch, A/T > Page 4138 Transmission Mode Switch: Description and Operation Transmission Mode Switch Transmission Control Switch (TCS) DESCRIPTION The Transmission Control Switch (TCS) is a momentary contact switch which disables 4th gear operation and enables engine braking when activated. OPERATION When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM). The PCM then energizes the Transmission Control Indicator Lamp (TCIL) and the Coast Clutch Solenoid (CCS), applying the coast clutch to provide engine braking and cancels fourth gear operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: Customer Interest A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 4157 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 4163 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission Transmission Position Switch/Sensor: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission > Page 4166 Transmission Position Switch/Sensor: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only > Page 4169 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission Transmission Position Switch/Sensor: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission > Page 4172 Transmission Position Switch/Sensor: Testing and Inspection With 4R70W Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Output Shaft Speed Sensor <--> [Transmission Speed Sensor, A/T] > Component Information > Locations Output Shaft Speed Sensor: Locations The Output Shaft Speed Sensor is located at the LH rear of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor PURPOSE Used as an input to determine shift schedule and Electronic Pressure Control (EPC) for temperature effects. DESCRIPTION The Transmission Fluid Temperature (TFT) sensor is a temperature-sensitive device called a thermistor it is located in the solenoid body assembly it sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with the transmission fluid temperature. OPERATION The PCM uses the voltage signal to determine whether a cold start shift schedule is necessary. The cold start shift schedule lowers shift speeds to allow for the reduced performance of cold engine operation. The TFT is part of the transmission solenoid assembly and is not replaced separately. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-16 > Oct > 03 > A/T - Harsh Shifts PROM - Programmable Read Only Memory: Customer Interest A/T - Harsh Shifts Article No. 03-21-16 10/06/03 TRANSMISSION - E40D - HARSH SHIFTS - 7.3L DIESEL BUILT BETWEEN 5/15/96 AND 7/8/96 CALIFORNIA CALIBRATION 6-90P-R11 ONLY FORD: 1996 E-350, F-250, F-350 Article 96-21-16 is being republished as part of a consolidated 7.3L diagnostic aid booklet. ISSUE Some 1996 7.3L diesel E40D equipped vehicles built between 5/15/96 and 7/8/96 may exhibit harsh upshifts. This may be caused by the Powertrain Control Module (PCM) calibration. ACTION Reprogram the PCM. The new calibration should reduce the possibility of harsh upshifts. Refer to the chart shown for details. SERVICE PROCEDURE WARNING THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE CALIBRATION. Perform normal diagnostics as outlined in the 1996 F-150-350 Series or Econoline Service Manual, Section 07-01 to verify no other causes of harsh shifts are present and service as required. If the condition still exists, reprogram the PCM. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 2S/pkg) 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. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-21-16 WARRANTY STATUS: INFORMATION ONLY Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-16 > Oct > 03 > A/T - Harsh Shifts > Page 4187 Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 96318 > Jan > 96 > Engine - Hard/No Start/Rough Idle/Stalls/Misses PROM - Programmable Read Only Memory: Customer Interest Engine - Hard/No Start/Rough Idle/Stalls/Misses Article No. 96-3-18 01/29/96 ^ HARD OR NO START - 7.3L DI TURBO - 1994-95 CALIBRATION ^ HESITATION - 7.3L DI TURBO - 1994-95 CALIBRATION ^ IDLE - ROUGH - 7.3L DI TURBO - 1994-95 CALIBRATION ^ LOW POWER - 7.3L DI TURBO - 1994-95 CALIBRATION ^ MISSES - 7.3L DI TURBO-1994-95 CALIBRATION ^ STALLS - 7.3L DI TURBO - 1994-95 CALIBRATION LIGHT TRUCK: 1994-95 F SUPER DUTY, F-250, F-350 1995 E-350 This TSB article is being republished in its entirety to update vehicle models and years. CALIBRATION: 5-89K-R00, 5-90A-R00, 5-90B-R00 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. ISSUE: Some 1994 and 1995 7.3L DI Turbo Diesels may have diagnostic difficulties or rough idle and performance concerns. These difficulties or concerns relate to: ^ Hard or no start ^ Stalls ^ Hesitation ^ Misses ^ Low power This is due to the limited diagnostics of the 1994 calibration and the diagnostic procedures. ACTION: For customer concern vehicles only, reprogram the Powertrain Control Module (PCM) to 1996 level calibration to provide improved diagnostic capability and performance. Refer to the following Service Procedure for details. NOTE: DO NOT REPROGRAM EITHER 1994 SELECTABLE RPM CONTROL VEHICLES OR RYDER, INC. UNIQUE CALIBRATION VEHICLES. USE THE SUPER STAR II TESTER TO DIAGNOSE THESE VEHICLES. Updating the calibration will allow the use of New Generation Star (NGS) tester and improved diagnostic procedures in diagnosing the vehicle. This will also slightly improve idle quality and performance. SERVICE PROCEDURE 1. Before servicing the vehicle, check for an Authorized Modifications Decal (FPS 8262) on the fan shroud. Vehicles which have already been reprogrammed should display a decal. 2. Connect Service Bay Diagnostic System (SBDS) to the J-1962 On-Board Diagnostics (OBD) II Data Link Connector which is located under the instrument panel below the glove compartment area. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 96318 > Jan > 96 > Engine - Hard/No Start/Rough Idle/Stalls/Misses > Page 4192 3. Reprogram the 1994 and 1995 Electronic Engine Control (EEC) module to 1996 level using the February, 1996 or later update CD-ROM and SBDS. Follow the directions and displays on the SBDS screen. 4. After reprogramming is complete, an Authorized Modifications Decal (FPS 8262) must be installed on the fan shroud. The decal must be completely filled out with the updated calibration information provided on the SBDS display screen. 5. Diagnostics must now be performed using the NGS scan tool and the 1996 Powertrain Control/Emissions Diagnosis (PC/ED) Manual diagnostic procedures. 6. Use the OBD II Data Link Connector located under the instrument panel for NGS and SBDS hook-up. 7. Select appropriate 1996 Service Manual on NGS scan tool to obtain correct Self-Test Modes and Parameter Identification (PID) menu. 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. In the future, if a 1994 or 1995 PCM requires replacing due to failure, the 1996 model year PCM should be ordered. Refer to the following Parts Block for correct part numbers. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-11-9, 95-06-05 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960318A Reprogram Powertrain 0.2 Hr. Control Module (PCM) Using Service Bay Diagnostic System (SBDS) 960318B Replace Powertrain Control 0.8 Hr. Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 08 OASIS CODES: 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 611000, 611500, 614000, 614500, 614600 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-21-10 > Oct > 03 > Engine - Hard Start, Rough Idle, Misfire, Stalls PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Hard Start, Rough Idle, Misfire, Stalls Article No. 03-21-10 10/06/03 HARD OR NO START - HESITATION - IDLE ROUGH - LOW POWER - MISSES - STALLS - 7.3L DI TURBO - 1994-95 CALIBRATION FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 96-3-18 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. NOTE THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE CALIBRATIONS. ISSUE Some 1994 and 1995 7.3L DI Turbo Diesels may have diagnostic difficulties or rough idle and performance concerns. These difficulties or concerns relate to: ^ Hard or no start ^ Stalls ^ Hesitation ^ Misses ^ Low power This is due to the limited diagnostics of the 1994-1995 calibration and the diagnostic procedures. ACTION For concern vehicles only, reprogram the Powertrain Control Module (PCM) to 1996 level calibration to provide improved diagnostic capability and performance. Refer to the following Service Procedure for details. NOTE DO NOT REPROGRAM EITHER 1994 SELECTABLE RPM CONTROL VEHICLES OR RYDER, INC. UNIQUE CALIBRATION VEHICLES. USE THE SUPER STAR II TESTER, OR NGS (SELF-TEST FUNCTIONS ONLY), TO DIAGNOSE THESE VEHICLES. Updating the calibration will allow the use of New Generation Star (NGS) tester and/or WDS and improved diagnostic procedures in diagnosing the vehicle. This will also slightly improve idle quality and performance. SERVICE PROCEDURE 1. Before servicing the vehicle, check for an Authorized Modifications Decal (FPS 8262) on the fan shroud. Vehicles which have already been reprogrammed should display a decal. 2. Connect the WDS or NGS to the vehicle. 3. Reprogram the 1994 and 1995 Electronic Engine Control (EEC) module to the latest level. Follow the directions and displays on the WDS or NGS screens. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-21-10 > Oct > 03 > Engine - Hard Start, Rough Idle, Misfire, Stalls > Page 4198 4. After reprogramming is complete, an Authorized Modifications Decal (FPS 8262) shown must be installed on the fan shroud. The decal must be completely filled out with the updated calibration information provided on the WDS or NGS display screen. 5. Diagnostics must now be performed using the NGS scan tool or WDS and the 1996 Powertrain Control/Emissions Diagnosis (PC/ED) Manual diagnostic procedures. 6. Use the OBD II Data Link Connector located under the instrument panel for NGS and WDS hook-up. 7. Select the appropriate 1996 Service Manual to obtain correct Self-Test Modes and Parameter Identification (PID) menu. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) 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. In the future, if a 1994 or 1995 PCM requires replacing due to failure, the 1996 model year PCM should be ordered. Refer to the Parts Block shown for correct part numbers. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-3-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-21-16 > Oct > 03 > A/T - Harsh Shifts PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Harsh Shifts Article No. 03-21-16 10/06/03 TRANSMISSION - E40D - HARSH SHIFTS - 7.3L DIESEL BUILT BETWEEN 5/15/96 AND 7/8/96 CALIFORNIA CALIBRATION 6-90P-R11 ONLY FORD: 1996 E-350, F-250, F-350 Article 96-21-16 is being republished as part of a consolidated 7.3L diagnostic aid booklet. ISSUE Some 1996 7.3L diesel E40D equipped vehicles built between 5/15/96 and 7/8/96 may exhibit harsh upshifts. This may be caused by the Powertrain Control Module (PCM) calibration. ACTION Reprogram the PCM. The new calibration should reduce the possibility of harsh upshifts. Refer to the chart shown for details. SERVICE PROCEDURE WARNING THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE CALIBRATION. Perform normal diagnostics as outlined in the 1996 F-150-350 Series or Econoline Service Manual, Section 07-01 to verify no other causes of harsh shifts are present and service as required. If the condition still exists, reprogram the PCM. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 2S/pkg) 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. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-21-16 WARRANTY STATUS: INFORMATION ONLY Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 03-21-16 > Oct > 03 > A/T - Harsh Shifts > Page 4203 Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips > Page 4208 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 96318 > Jan > 96 > Engine - Hard/No Start/Rough Idle/Stalls/Misses PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Hard/No Start/Rough Idle/Stalls/Misses Article No. 96-3-18 01/29/96 ^ HARD OR NO START - 7.3L DI TURBO - 1994-95 CALIBRATION ^ HESITATION - 7.3L DI TURBO - 1994-95 CALIBRATION ^ IDLE - ROUGH - 7.3L DI TURBO - 1994-95 CALIBRATION ^ LOW POWER - 7.3L DI TURBO - 1994-95 CALIBRATION ^ MISSES - 7.3L DI TURBO-1994-95 CALIBRATION ^ STALLS - 7.3L DI TURBO - 1994-95 CALIBRATION LIGHT TRUCK: 1994-95 F SUPER DUTY, F-250, F-350 1995 E-350 This TSB article is being republished in its entirety to update vehicle models and years. CALIBRATION: 5-89K-R00, 5-90A-R00, 5-90B-R00 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. ISSUE: Some 1994 and 1995 7.3L DI Turbo Diesels may have diagnostic difficulties or rough idle and performance concerns. These difficulties or concerns relate to: ^ Hard or no start ^ Stalls ^ Hesitation ^ Misses ^ Low power This is due to the limited diagnostics of the 1994 calibration and the diagnostic procedures. ACTION: For customer concern vehicles only, reprogram the Powertrain Control Module (PCM) to 1996 level calibration to provide improved diagnostic capability and performance. Refer to the following Service Procedure for details. NOTE: DO NOT REPROGRAM EITHER 1994 SELECTABLE RPM CONTROL VEHICLES OR RYDER, INC. UNIQUE CALIBRATION VEHICLES. USE THE SUPER STAR II TESTER TO DIAGNOSE THESE VEHICLES. Updating the calibration will allow the use of New Generation Star (NGS) tester and improved diagnostic procedures in diagnosing the vehicle. This will also slightly improve idle quality and performance. SERVICE PROCEDURE 1. Before servicing the vehicle, check for an Authorized Modifications Decal (FPS 8262) on the fan shroud. Vehicles which have already been reprogrammed should display a decal. 2. Connect Service Bay Diagnostic System (SBDS) to the J-1962 On-Board Diagnostics (OBD) II Data Link Connector which is located under the instrument panel below the glove compartment area. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 96318 > Jan > 96 > Engine - Hard/No Start/Rough Idle/Stalls/Misses > Page 4213 3. Reprogram the 1994 and 1995 Electronic Engine Control (EEC) module to 1996 level using the February, 1996 or later update CD-ROM and SBDS. Follow the directions and displays on the SBDS screen. 4. After reprogramming is complete, an Authorized Modifications Decal (FPS 8262) must be installed on the fan shroud. The decal must be completely filled out with the updated calibration information provided on the SBDS display screen. 5. Diagnostics must now be performed using the NGS scan tool and the 1996 Powertrain Control/Emissions Diagnosis (PC/ED) Manual diagnostic procedures. 6. Use the OBD II Data Link Connector located under the instrument panel for NGS and SBDS hook-up. 7. Select appropriate 1996 Service Manual on NGS scan tool to obtain correct Self-Test Modes and Parameter Identification (PID) menu. 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. In the future, if a 1994 or 1995 PCM requires replacing due to failure, the 1996 model year PCM should be ordered. Refer to the following Parts Block for correct part numbers. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-11-9, 95-06-05 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960318A Reprogram Powertrain 0.2 Hr. Control Module (PCM) Using Service Bay Diagnostic System (SBDS) 960318B Replace Powertrain Control 0.8 Hr. Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 08 OASIS CODES: 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 611000, 611500, 614000, 614500, 614600 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 03-21-10 > Oct > 03 > Engine - Hard Start, Rough Idle, Misfire, Stalls PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Hard Start, Rough Idle, Misfire, Stalls Article No. 03-21-10 10/06/03 HARD OR NO START - HESITATION - IDLE ROUGH - LOW POWER - MISSES - STALLS - 7.3L DI TURBO - 1994-95 CALIBRATION FORD: 1994-1995 F SUPER DUTY, F-250, F-350 1995 E-350 Article 96-3-18 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. NOTE THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE CALIBRATIONS. ISSUE Some 1994 and 1995 7.3L DI Turbo Diesels may have diagnostic difficulties or rough idle and performance concerns. These difficulties or concerns relate to: ^ Hard or no start ^ Stalls ^ Hesitation ^ Misses ^ Low power This is due to the limited diagnostics of the 1994-1995 calibration and the diagnostic procedures. ACTION For concern vehicles only, reprogram the Powertrain Control Module (PCM) to 1996 level calibration to provide improved diagnostic capability and performance. Refer to the following Service Procedure for details. NOTE DO NOT REPROGRAM EITHER 1994 SELECTABLE RPM CONTROL VEHICLES OR RYDER, INC. UNIQUE CALIBRATION VEHICLES. USE THE SUPER STAR II TESTER, OR NGS (SELF-TEST FUNCTIONS ONLY), TO DIAGNOSE THESE VEHICLES. Updating the calibration will allow the use of New Generation Star (NGS) tester and/or WDS and improved diagnostic procedures in diagnosing the vehicle. This will also slightly improve idle quality and performance. SERVICE PROCEDURE 1. Before servicing the vehicle, check for an Authorized Modifications Decal (FPS 8262) on the fan shroud. Vehicles which have already been reprogrammed should display a decal. 2. Connect the WDS or NGS to the vehicle. 3. Reprogram the 1994 and 1995 Electronic Engine Control (EEC) module to the latest level. Follow the directions and displays on the WDS or NGS screens. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 03-21-10 > Oct > 03 > Engine - Hard Start, Rough Idle, Misfire, Stalls > Page 4219 4. After reprogramming is complete, an Authorized Modifications Decal (FPS 8262) shown must be installed on the fan shroud. The decal must be completely filled out with the updated calibration information provided on the WDS or NGS display screen. 5. Diagnostics must now be performed using the NGS scan tool or WDS and the 1996 Powertrain Control/Emissions Diagnosis (PC/ED) Manual diagnostic procedures. 6. Use the OBD II Data Link Connector located under the instrument panel for NGS and WDS hook-up. 7. Select the appropriate 1996 Service Manual to obtain correct Self-Test Modes and Parameter Identification (PID) menu. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) 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. In the future, if a 1994 or 1995 PCM requires replacing due to failure, the 1996 model year PCM should be ordered. Refer to the Parts Block shown for correct part numbers. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-3-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Reprogramming Tips Article No. 97-9-8 04/28/97 POWERTRAIN CONTROL MODULE - REPROGRAM POWERTRAIN CONTROL MODULE (PCM) - SERVICE PROCEDURES - SERVICE TIP FORD: 1994-97 CROWN VICTORIA, MUSTANG, THUNDERBIRD 1996-97 CONTOUR, ESCORT, PROBE, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR, GRAND MARQUIS 1995-97 CONTINENTAL, TOWN CAR 1996-97 MARK VIII, MYSTIQUE, SABLE, TRACER LIGHT TRUCK: 1994-97 ECONOLINE, F-150-350 SERIES 1995-97 RANGER 1995-98 WINDSTAR 1996 BRONCO 1996-97 AEROSTAR, EXPLORER 1997 EXPEDITION, MOUNTAINEER This TSB article is being republished in its entirety to include Windstar. ISSUE: Powertrain Control Modules (PCMs) no longer need to be replaced when servicing driveability concerns. The only time a PCM needs replacing is when it can no longer be reprogrammed and/or is damaged. In all other cases, the PCM must be reprogrammed and NOT REPLACED. ACTION: Use the following Service Procedure to properly reprogram a PCM. SERVICE PROCEDURE PCM REPROGRAMMING USING SBDS 1. At the Main menu, select Powertrain and enter the Vehicle Identification Number (VIN). Select "Continue." 2. From the Powertrain menu, select Electronic Engine category. 3. Scroll through the "Tool List" to PCM Reprogramming and select "Continue." 4. Any TSBs or Recalls for the entered vehicle will be displayed. There is up to a 6 week delay for TSB/Recall information updates on SBDS. New TSBs/Recalls may not appear or only the TSB number will be displayed even though the new calibration is on the current calibration CD-ROM. Also, if the vehicle calibration is being updated because of a Special Service Message, Broadcast Message or the PCM was replaced and requires calibration, no screen may appear. This is not a concern and will not prevent programming updates or being paid for programming updates. 5. Follow all hook-up instructions and continue as prompted to the calibration screen. Typically, a list of calibration numbers will appear. Answer as appropriate for the vehicle and select "Continue." SBDS will then validate the information entered against the information read in the PCM, and any mismatch of software or hardware will be displayed for technician action. 6. Insert the proper calibration or the latest level CD-ROM when prompted and follow the instructions as displayed by SBDS. Do not crank the engine. SBDS will update the engine calibration to the latest level calibration for the selected calibration. 7. After programming is complete, SBDS will display a representation of the Authorized Modification Decal with the Engineering Part Number for the PCM installed. It is important that the label be completed and attached to the vehicle. S8DS will also automatically print a copy of the vehicle log for filing with the Repair Order. 8. Selecting "Continue" will call for a KOEO self test. Any hard faults present after performing self test were not caused by reprogramming. The calibration has now been validated and the PCM is operating properly. Unless directed by other Service Procedures, the vehicle can be released to Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 97-9-8 > Apr > 97 > PCM - Reprogramming Tips > Page 4224 the customer. PCM REPROGRAMMING WITH SBTS/NGS 1. Select "NGS," then follow procedure "Touring PLM Recalibration." 2. Be sure to use cable with oversized DCL connector. The oversized connector incorporates an 18-volt transformer supplying the required voltage to reprogram the PCM. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-25-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 690000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Description and Operation Electronic Pressure Control Solenoid: Description and Operation DESCRIPTION The Electronic Pressure Control (EPC) Solenoid is a Variable Force Solenoid. The VFS-type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. OPERATION The EPC solenoid supplies Electronic Pressure Control which regulates transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and the line modulator circuits. These two pressures control the clutch application pressures. CAUTION: The electronic pressure control pressure output from the variable force solenoid is NOT adjustable. Any modification to the electronic pressure control solenoid will affect the transmission warranty. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove steering column. 2. Unclip wire terminal from shift interlock actuator. 3. Remove two screws from insert plate and shift interlock actuator. INSTALLATION 1. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Description and Operation Electronic Pressure Control Solenoid: Description and Operation DESCRIPTION The Electronic Pressure Control (EPC) Solenoid is a Variable Force Solenoid. The VFS-type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. OPERATION The EPC solenoid supplies Electronic Pressure Control which regulates transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and the line modulator circuits. These two pressures control the clutch application pressures. CAUTION: The electronic pressure control pressure output from the variable force solenoid is NOT adjustable. Any modification to the electronic pressure control solenoid will affect the transmission warranty. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove steering column. 2. Unclip wire terminal from shift interlock actuator. 3. Remove two screws from insert plate and shift interlock actuator. INSTALLATION 1. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-9-6 > May > 99 > A/T 4R70W (Remanufactured) Delayed or No 2-3 Upshift Accumulator: Customer Interest A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Article No. 99-9-6 05/17/99 FORD: 1994-1997 THUNDERBIRD 1995-1998 CROWN VICTORIA 1996-1998 MUSTANG LINCOLN-MERCURY: 1993-1998 MARK VIII 1994-1997 COUGAR 1995-1998 GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1994-1998 ECONOLINE, F-150 1996-1998 EXPLORER 1997-1998 EXPEDITION, F-25O LD, MOUNTAINEER This concern is ONLY for vehicles with Ford Quality Remanufactured (FQR) 4R70W Transmission Exchange Units With Julian build dates between 062-97 And 04099 (corresponding serial numbers are between R0475797 and R0771887). ISSUE A delayed or no 2-3 upshift, primarily when the transmission is cold, may be evident on some vehicles In some cases, Diagnostic Trouble Code (DTC) P0782 may also be present. This may be caused by fluid pressure leakage past the larger diameter seal of the 2-3 accumulator. ACTION Replace the 2-3 accumulator piston using a revised piston. The revised piston will increase seal/bore interference, eliminating any internal leak relating to the 2-3 accumulator piston reducing the possibility of 2-3 upshift concerns. Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Piston OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990906A Replace Accumulator 1.0 Hr. Piston DEALER CODING CONDITION BASIC PART NO. CODE 7H292 42 OASIS CODES: 501000, 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 97-11-11 > May > 97 > A/T AODE/4R70W Erratic/Prolonged 1-2 Shift Accumulator: Customer Interest A/T - AODE/4R70W Erratic/Prolonged 1-2 Shift Article No. 97-11-11 05/27/97 ^ TRANSMISSION - 4R70W - ERRATIC OR PROLONGED 1-2 SHIFT ^ TRANSMISSION - AODE - ERRATIC OR PROLONGED 1-2 SHIFT FORD: 1992-97 CROWN VICTORIA 1994-97 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-97 GRAND MARQUIS, TOWN CAR 1993-97 MARK VIII 1994-97 COUGAR LIGHT TRUCK: 1994-97 ECONOLINE, F-150 1996-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER ISSUE: Some vehicles may exhibit an erratic or prolonged 1-2 shift. This may be caused by early Accumulator Seal wear which may occur during repeated 1-2, 2-1 shift cycling. The Accumulator side loads in the Case Accumulator Bore and causes the Case Bore to become scuffed. Bore scuffing leads to premature seal wear and eventual intermediate clutch pressure loss, which leads to the loss in 1-2 shift. ACTION: Replace the cast aluminum piston with the one-piece stamped steel piston with bonded lip seals and replace the top Accumulator Spring. These revised parts allow for increased durability. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: TRANSMISSION CASE REPLACEMENT IS NOT REQUIRED DUE TO 1-2 SHIFT ACCUMULATOR BORE SCUFFING. THE REVISED PISTON ASSEMBLY CAN BE USED WITH SCUFFED SEAL BORE. 1. With the vehicle on a hoist, remove the transmission pan and gasket. Using the Snap Ring Removal Tool, remove the 1-2 Accumulator Piston Retainer. At this time, the spring load will pop the cover and bottom Accumulator Spring out of the bore. 2. Remove the piston and top Accumulator Spring. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 97-11-11 > May > 97 > A/T AODE/4R70W Erratic/Prolonged 1-2 Shift > Page 4254 3. Replace the piston and top Accumulator Spring with the new bonded Piston (F7AZ-7F251-AA) and spring (refer to Figure 1 for applications). If not damaged, reinstall the bottom Accumulator Spring and cover. 4. Reinstall the retaining ring. NOTE: DO NOT REUSE THE TRANSMISSION PAN GASKET IF IT IS DAMAGED. 5. Install the transmission pan and gasket. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 97-11-11 > May > 97 > A/T AODE/4R70W Erratic/Prolonged 1-2 Shift > Page 4255 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971111A Replace 1-2 Accumulator 0.9 Hr. Components As Required (Includes Pan Removal And Installation) - All Vehicles 971111B Add Time To Clean, 0.1 Hr. Inspect And Reuse Pan Gasket 971111C Post Repair Road Test 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7F249 70 OASIS CODES: 501000, 502000, 503000, 504000, 590000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-9-6 > May > 99 > A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Accumulator: All Technical Service Bulletins A/T - 4R70W (Remanufactured) Delayed or No 2-3 Upshift Article No. 99-9-6 05/17/99 FORD: 1994-1997 THUNDERBIRD 1995-1998 CROWN VICTORIA 1996-1998 MUSTANG LINCOLN-MERCURY: 1993-1998 MARK VIII 1994-1997 COUGAR 1995-1998 GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1994-1998 ECONOLINE, F-150 1996-1998 EXPLORER 1997-1998 EXPEDITION, F-25O LD, MOUNTAINEER This concern is ONLY for vehicles with Ford Quality Remanufactured (FQR) 4R70W Transmission Exchange Units With Julian build dates between 062-97 And 04099 (corresponding serial numbers are between R0475797 and R0771887). ISSUE A delayed or no 2-3 upshift, primarily when the transmission is cold, may be evident on some vehicles In some cases, Diagnostic Trouble Code (DTC) P0782 may also be present. This may be caused by fluid pressure leakage past the larger diameter seal of the 2-3 accumulator. ACTION Replace the 2-3 accumulator piston using a revised piston. The revised piston will increase seal/bore interference, eliminating any internal leak relating to the 2-3 accumulator piston reducing the possibility of 2-3 upshift concerns. Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Piston OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990906A Replace Accumulator 1.0 Hr. Piston DEALER CODING CONDITION BASIC PART NO. CODE 7H292 42 OASIS CODES: 501000, 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 97-11-11 > May > 97 > A/T - AODE/4R70W Erratic/Prolonged 1-2 Shift Accumulator: All Technical Service Bulletins A/T - AODE/4R70W Erratic/Prolonged 1-2 Shift Article No. 97-11-11 05/27/97 ^ TRANSMISSION - 4R70W - ERRATIC OR PROLONGED 1-2 SHIFT ^ TRANSMISSION - AODE - ERRATIC OR PROLONGED 1-2 SHIFT FORD: 1992-97 CROWN VICTORIA 1994-97 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-97 GRAND MARQUIS, TOWN CAR 1993-97 MARK VIII 1994-97 COUGAR LIGHT TRUCK: 1994-97 ECONOLINE, F-150 1996-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER ISSUE: Some vehicles may exhibit an erratic or prolonged 1-2 shift. This may be caused by early Accumulator Seal wear which may occur during repeated 1-2, 2-1 shift cycling. The Accumulator side loads in the Case Accumulator Bore and causes the Case Bore to become scuffed. Bore scuffing leads to premature seal wear and eventual intermediate clutch pressure loss, which leads to the loss in 1-2 shift. ACTION: Replace the cast aluminum piston with the one-piece stamped steel piston with bonded lip seals and replace the top Accumulator Spring. These revised parts allow for increased durability. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: TRANSMISSION CASE REPLACEMENT IS NOT REQUIRED DUE TO 1-2 SHIFT ACCUMULATOR BORE SCUFFING. THE REVISED PISTON ASSEMBLY CAN BE USED WITH SCUFFED SEAL BORE. 1. With the vehicle on a hoist, remove the transmission pan and gasket. Using the Snap Ring Removal Tool, remove the 1-2 Accumulator Piston Retainer. At this time, the spring load will pop the cover and bottom Accumulator Spring out of the bore. 2. Remove the piston and top Accumulator Spring. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 97-11-11 > May > 97 > A/T - AODE/4R70W Erratic/Prolonged 1-2 Shift > Page 4265 3. Replace the piston and top Accumulator Spring with the new bonded Piston (F7AZ-7F251-AA) and spring (refer to Figure 1 for applications). If not damaged, reinstall the bottom Accumulator Spring and cover. 4. Reinstall the retaining ring. NOTE: DO NOT REUSE THE TRANSMISSION PAN GASKET IF IT IS DAMAGED. 5. Install the transmission pan and gasket. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 97-11-11 > May > 97 > A/T - AODE/4R70W Erratic/Prolonged 1-2 Shift > Page 4266 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971111A Replace 1-2 Accumulator 0.9 Hr. Components As Required (Includes Pan Removal And Installation) - All Vehicles 971111B Add Time To Clean, 0.1 Hr. Inspect And Reuse Pan Gasket 971111C Post Repair Road Test 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7F249 70 OASIS CODES: 501000, 502000, 503000, 504000, 590000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Page 4267 Accumulator: Service and Repair 3 - 4 SHIFT VALVE REMOVAL & INSTALLATION 1. Remove valve body. 2. Compress 3-4 accumulator piston cover, then remove snap ring retainer. 3. Release cover slowly, then remove piston cover, return spring and piston. Some models do not use a spring. 4. Remove seal from 3-4 accumulator cover and piston and inspect for damage and wear. 5. Install new seals on 3-4 accumulator cover, if necessary. Lubricate cover pocket of case with transmission fluid. 6. Install 3-4 accumulator piston and return spring into case, then the cover. 7. Compress cover using suitable tool, then install snap ring. Ensure cover is reseated snugly against snap ring. 8. Install valve body, filter, pan and gasket. Refill transmission pan to proper fluid level. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications Band: Specifications Band Adjusting Screw Locknut 35-45 ft.lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 4271 Band: Description and Operation DESCRIPTION AND OPERATION The band holds the intermediate brake drum stationary during manual 2nd. The band also prevents the intermediate one-way clutch from overrunning during coast. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications > Page 4272 Band: Adjustments 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Redesigned Intermediate Band Apply Servo Band Apply Servo: Technical Service Bulletins A/T - E4OD Redesigned Intermediate Band Apply Servo Article No. 95-23-14 11/20/95 TRANSMISSION - E4OD - NEW DESIGN INTERMEDIATE BAND APPLY SERVO ASSEMBLY LIGHT TRUCK: 1989-96 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES ISSUE: All E4OD transmissions built after August 7, 1995 have a new design Intermediate Band Apply Servo Assembly (F6TZ-7D021-A). This new design will service all past and present model E4OD transmissions. ACTION: When replacement of the Intermediate Band Apply Servo Assembly becomes necessary, either design (previous or new) can be used. Some transmissions built after August 7, 1995 do not have the retaining ring groove in the piston bore and only the new design piston and seal assembly can be used. Refer to Figure 1. CAUTION: WHEN USING THE NEW DESIGN PISTON AND SEAL ASSEMBLY, DO NOT USE THE PISTON ASSEMBLY RETAINER OR RETAINING RING. PART NUMBER PART NAME F6TZ-7D021-A Intermediate Band Apply Servo Assembly OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Removal and Installation Band Apply Servo: Service and Repair Removal and Installation Servo Apply Lever - With C6 REMOVAL CAUTION: All parts must be handled carefully to avoid nicking or burring the bearing or mating surfaces. Lubricate all internal parts with clean automatic transmission fluid before assembling them. Do not use any other lubricants except on gaskets and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and seals when assembling transmission. Cup Plug Installation 1. Working from inside of case, carefully drive on servo apply lever to remove cup plug. The shaft can be withdrawn from the case by hand. INSTALLATION 1. Drive the cup plug into position using fabricated tool shown in the Cup Plug Installation image. Make certain the plug is flush with the counterbore. NOTE: Coat the plug with Loctite before installation. Servo Assembly REMOVAL 1. Raise vehicle and remove engine rear support to crossmember bolt. 2. Remove two crossmember to frame attaching bolts, then raise transmission enough to remove weight from crossmember and remove crossmember. 3. Disconnect muffler inlet pipe from exhaust manifolds and let pipe hang. 4. Place drain pan under servo and remove servo cover to transmission case attaching bolts. 5. Remove servo cover, piston, spring, and gasket from case, turning band adjusting screw inward as piston is removed. This ensures there will be enough tension on the band to keep the struts properly engaged in the band end notches while the piston is removed. 6. Apply air pressure to port in servo cover to remove piston and stem. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Removal and Installation > Page 4279 Intermediate Servo Assembly 7. Remove seals from piston and cover. NOTE: Replace complete piston and rod assembly if piston or piston sealing lips are damaged. INSTALLATION 1. Lubricate new seals with transmission fluid, then install in cover and piston. 2. Lubricate piston with transmission fluid and install in cover. 3. Position new gasket on servo cover and spring on piston rod. 4. Insert piston and cover in case. Secure cover with bolts, carefully backing off band adjusting screw while torquing cover bolts to 14-20 ft lbs. Ensure vent tube retaining clip is in place. 5. Connect muffler inlet pipe to exhaust manifolds. 6. Raise transmission high enough to install engine rear support. Secure support to extension housing. Lower transmission as required to install support to crossmember bolt. 7. Remove jack and adjust band. 8. Lower vehicle, then add fluid as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Removal and Installation > Page 4280 Band Apply Servo: Service and Repair In-Vehicle Repairs Low-Reverse Servo WARNING: Low-reverse servo piston is under spring pressure. Use caution when removing servo piston cover. REMOVAL & INSTALLATION 1. Remove valve body. 2. Compress low-reverse servo piston cover with a suitable tool, then remove snap ring retainer. 3. Using servo piston removal tool T80L-77030-B, or equivalent, apply compressed air to servo piston release passage and remove servo piston cover and spring. Remove piston from cover, then rubber seal from piston and cover. 4. Install new seals on servo piston and cover. 5. Lubricate all seals, piston and piston bore with transmission fluid. 6. Install servo piston into cover, then return spring into servo piston. 7. Install piston assembly into servo bore. 8. Compress piston using suitable tool, then install snap ring retainer. 9. Install valve body, filter, pan and gasket. Refill transmission to proper fluid level. Overdrive Servo Assembly REMOVAL & INSTALLATION 1. Remove valve body as previously described. 2. Compress overdrive servo piston cover with a suitable tool, then remove snap ring retainer. 3. Using servo piston removal tool No. T80L-77030-B or equivalent, apply compressed air to servo piston release passage and remove the overdrive servo piston cover and spring. Remove piston from cover, then the rubber seal from piston and cover. 4. Install new servo piston and cover seals on the servo piston and cover. 5. Lubricate all seals, piston and piston bore with transmission fluid. 6. Install servo piston into cover, then the return spring into servo piston. 7. Install overdrive piston assembly into overdrive servo bore. 8. Compress overdrive piston using suitable tool, then install snap ring retainer. 9. Install valve body, filter, pan and gasket. Refill transmission to proper fluid level. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Description and Operation Brake Switch - TCC: Description and Operation Brake On/Off (BOO) Switch DESCRIPTION The Brake On/0ff switch tells the powertrain control module when the brakes are applied. The switch is closed when the brakes are applied and open when they are released. FUNCTION Disengages torque converter clutch when brake is applied. RELATED SYMPTOMS Failed on or not connected - Torque converter clutch will not engage at less than 1/3 throttle. Failed off - Torque converter clutch will not disengage when brake is applied. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Service Case Replacement Service Tips Case: Technical Service Bulletins A/T - E4OD Service Case Replacement Service Tips Article No. 98-13-21 07/06/98 TRANSMISSION - E4OD - SERVICE CASE REPLACEMENT SERVICE TIPS FOR 7.3L DIESEL VEHICLE APPLICATIONS LIGHT TRUCK: 1989-95 ECONOLINE, F SUPER DUTY, F-25O HD ISSUE Some 1989-95 transmission service cases for 7.3L diesel applications may not have all valve body checkball locations cast into the case wormtrail. This may be due to one of the service case dies being changed. ACTION When replacing the transmission case on any 1989-95 vehicle equipped with 7.3L diesel and E4OD transmission, refer to the following Service Procedure and Part Usage Charts for specific details by model year on required part usage. It details required mating components with the case change. SERVICE PROCEDURE NOTE NEW SERVICE MAIN CONTROLS ARE REQUIRED DUE TO INCOMPATIBILITY BETWEEN THE DIESEL SERVICE CASE WORMTRAIL AND THE ORIGINAL MAIN CONTROL ASSEMBLIES. 1989-94 VEHICLES EQUIPPED WITH 7.3L DIESEL AND E4OD TRANSMISSION When using a new service case, refer to the main control assembly, large separator plate and gaskets chart for parts usage: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Service Case Replacement Service Tips > Page 4288 NOTE ADDITIONALLY, INSTALL EIGHT (8) RUBBER CHECKBALLS AND ONE (1) STEEL (EPC) CHECKBALL PER FIGURE 1. 1995 VEHICLES EQUIPPED WITH 7.3L DIESEL AND E4OD TRANSMISSION When using a new service case, refer to the main control assembly, large separator plate and gaskets chart for parts usage: NOTE ADDITIONALLY, INSTALL EIGHT (8) RUBBER CHECKBALLS AND ONE (1) STEEL (EPC) CHECKBALL PER FIGURE 1. PART NUMBER PART NAME F7TZ-7005-EA case Assembly F6TZ-7A100-B Main control F6TZ-7A100-D Main Control F5TZ-7A008-B Separator Plate F6TZ-7A008-B Separator Plate F81Z-7D100-AA Gasket F81Z-7D100-AB Gasket F6TZ-7C155-A Gasket OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Service Case Replacement Service Tips > Page 4289 OASIS CODES: 501000, 502000, 503000, 503300, 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Reverse Clutch Piston and Seal Usage Clutch: Technical Service Bulletins A/T - E4OD Reverse Clutch Piston and Seal Usage Article No. 96-7-28 03/25/96 TRANSMISSION - E4OD - REVERSE CLUTCH PISTON AND PISTON SEAL USAGE - SERVICE TIP LIGHT TRUCK: 1989-96 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES ISSUE: The reverse clutch has changed for the 1996 model year. The changes are as follows: ^ addition of a cushion spring to the reverse clutch pack ^ reverse clutch piston depth changed to allow additional cushion spring ^ retainer and spring assembly changed to allow additional cushion spring ^ inner piston seal changed from square cut to lip seal ^ outer piston seal changed from square cut to lip seal These changes are not interchangeable with past models due to calibration. ACTION: When replacement of any reverse clutch component is necessary, refer to the Part Usage Chart for the correct part to use for the particular vehicle application. NOTE: SERVICE OVERHAUL KITS DO NOT CONTAIN THE 1996 LEVEL COMPONENTS. THEY MUST BE PURCHASED SEPARATELY AT THIS TIME. CAUTION: MIXING ANY OF THE COMPONENTS LISTED IN THE PART USAGE CHART COULD CAUSE ENGAGEMENT AND/OR SHIFT CONCERNS. CAUTION: USING ANY OF THE COMPONENTS LISTED IN THE PART USAGE CHART IN ANY OTHER WAY THAN RECOMMENDED BY THIS CHART COULD CAUSE ENGAGEMENT AND/OR SHIFT CONCERNS. Parts Block Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Reverse Clutch Piston and Seal Usage > Page 4294 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Reverse Clutch Piston and Seal Usage > Page 4295 Clutch: Technical Service Bulletins A/T - E40D Overdrive One Way Clutch Tips Article No. 95-6-18 03/27/95 TRANSMISSION - E4OD - OVERDRIVE ONE-WAY CLUTCH - SERVICE TIPS LIGHT TRUCK: 1989-95 BRONCO, E-30, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: There are two (2) Overdrive One-Way Clutch Assemblies available for service. ACTION: Refer to the Application Chart for correct overdrive clutch usage. PART NUMBER PART NAME F4TZ-7A089-A Overdrive One-Way Clutch F5TZ-7A089-A Overdrive One-Way Clutch OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Reverse Clutch Piston and Seal Usage > Page 4296 Clutch: Technical Service Bulletins A/T - E4OD Direct Clutch Plate Usage Chart/Service Tip Article No. 95-25-13 12/18/95 TRANSMISSION - E4OD - DIRECT CLUTCH PLATE USAGE CHART - SERVICE TIP LIGHT TRUCK: 1989-96 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES ISSUE: The direct clutch friction plates in the E4OD transmission have changed for 1996. These revised clutch plates have grooves in the friction material. Refer to Figures 1 and 2. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Reverse Clutch Piston and Seal Usage > Page 4297 ACTION: If replacement of the direct clutch friction plates is necessary, refer to the Application Chart for correct part usage. Using the incorrect friction plate could result in a shift concern. PART NUMBER PART NAME E9TZ-7B164-D Direct Clutch Plate F6TZ-7B164-B Direct Clutch Plate OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - E4OD Reverse Clutch Piston and Seal Usage > Page 4298 Clutch: Technical Service Bulletins A/T - E4OD Intermediate Brake Drum Assembly Service Tip Article No. 95-16-19 08/14/95 TRANSMISSION - E4OD - INTERMEDIATE BRAKE DRUM ASSEMBLY USAGE - SERVICE TIP LIGHT TRUCK: 1989-95 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES ISSUE: Starting with the 1995 model year, the intermediate brake drum assembly will for correct part usage. have one (1) direct clutch apply pressure feed hole instead of two (2). Incorrect usage of the intermediate brake drum assembly may result in 2-3 shift and/or reverse engagement concerns. ACTION: Refer to the Application Chart APPLICATION CHART Model Year Part Number Number Of Clutch Plates 1989-94 (Two Feed Holes) E9TZ-7D044-A 3/4 1995 (One Feed Hole) F5TZ-7D044-A 3/4 1995 (One Feed Hole) F5TZ-7D044-B 5 PART NUMBER PART NAME E9TZ-7D044-A Intermediate Brake Drum F5TZ-7D044-A Intermediate Brake Drum F5TZ-7D044-B Intermediate Brake Drum OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 503000, 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Direct Clutch Clutch: Description and Operation Direct Clutch DESCRIPTION AND OPERATION The direct clutch holds the forward clutch cylinder to the intermediate brake drum during third, fourth, and reverse gears. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Direct Clutch > Page 4301 Clutch: Description and Operation Forward Clutch DESCRIPTION AND OPERATION The forward clutch holds the forward clutch cylinder to the forward ring gear during all forward gears. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Direct Clutch > Page 4302 Clutch: Description and Operation Intermediate Clutch DESCRIPTION AND OPERATION The intermediate clutch holds the outer race of the intermediate one-way clutch to the case during second, third, and fourth gears. The intermediate one-way sprag clutch holds the intermediate clutch to the intermediate brake drum, input shell and forward-reverse sun gear during drive in second gear and overruns in coast, third and fourth gear. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Direct Clutch > Page 4303 Clutch: Description and Operation Low Clutch WITH E4OD DESCRIPTION AND OPERATION The low-reverse one-way roller clutch holds the reverse hub and the reverse planetary carrier to the case during drive in first gear and overruns in coast and all other forward gears. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Direct Clutch > Page 4304 Clutch: Description and Operation Direct Clutch DESCRIPTION AND OPERATION The direct clutch holds the forward clutch cylinder to the intermediate brake drum during third, fourth, and reverse gears. Forward Clutch DESCRIPTION AND OPERATION The forward clutch holds the forward clutch cylinder to the forward ring gear during all forward gears. Intermediate Clutch DESCRIPTION AND OPERATION The intermediate clutch holds the outer race of the intermediate one-way clutch to the case during second, third, and fourth gears. The intermediate one-way sprag clutch holds the intermediate clutch to the intermediate brake drum, input shell and forward-reverse sun gear during drive in second gear and overruns in coast, third and fourth gear. Low Clutch WITH E4OD DESCRIPTION AND OPERATION The low-reverse one-way roller clutch holds the reverse hub and the reverse planetary carrier to the case during drive in first gear and overruns in coast and all other forward gears. Overdrive Clutch DESCRIPTION AND OPERATION The overdrive clutch holds the coast clutch cylinder and overdrive sun gear to the case during fourth gear. The overdrive clutch also enables the overdrive planetary gear to walk around the sun gear and the overdrive ring gear. The overdrive one-way sprag clutch holds the overdrive ring gear to the overdrive sun gear during drive in first, second, and third gear and overruns during coast and fourth gear. Reverse Clutch DESCRIPTION AND OPERATION The reverse clutch holds the reverse hub to the case during reverse and manual one. The reverse clutch also prevents the low-reverse one-way clutch from overrunning during reverse and coast in manual one. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch Clutch: Service and Repair Coast Clutch Disassemble Exploded View Of Coast Clutch Cylinder NOTE: Refer to the Exploded View Of Coast Clutch Cylinder when performing the following procedure. 1. Remove overdrive sun gear from coast clutch cylinder. 2. Remove and discard selective snap ring. 3. Remove pressure and clutch plates from cylinder. Tag for assembly reference. 4. Using clutch spring compressor No. T65L-77515-A or equivalent, remove return spring retaining ring. 5. Remove compressor tool. 6. Remove piston return spring, piston apply plate, and piston from cylinder. 7. Remove outer seal from piston, then the inner seal from cylinder. Assemble NOTE: Soak all friction plates in clean transmission fluid for fifteen minutes. Lightly lubricate all 0-ring seals before installing, using transmission fluid. 1. Install inner seal, with lip facing down, into cylinder. 2. Install outer seal, with lip facing down, onto piston. 3. Install piston, piston apply plate, and piston return spring into cylinder. 4. Using clutch spring compressor No. T65L-7751 5-A or equivalent, install return spring retaining ring. 5. Install clutch pack plates, alternately starting with steel plate. 6. Install pressure plate. 7. Install selective snap ring. Using feeler gauge, check stack-up at 3 different points 120° apart. 8. Clearance for 2 plate is 0.052-0.027 inch and clearance for 3 plate is 0.064-0.039 inch. 9. If clearance is not within specifications, install correct selective snap ring and recheck. Selective snap rings are available in following sizes: sizes available are 0.061-0.057 inch, 0.081-0.077, 0.102-0.098, 0.122-0.118, and 0.142-0.138 inch. 10. Install overdrive sun gear, with short end of gear down, into coast clutch cylinder. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4307 Clutch: Service and Repair Forward Clutch Forward Carrier REMOVAL 1. Remove needle bearing assembly from carrier. 2. Remove thrust washer from front side of carrier. INSTALLATION 1. Reverse procedure to install, noting the following: a. Thrust washer tabs go into carrier. b. Install notched inner race facing outward. Forward Hub and Ring Gear REMOVAL 1. Remove plastic thrust washer No. 7D090 from front face of hub. 2. Remove snap ring, then the forward hub from ring gear. INSTALLATION 1. Reverse procedure to install. With C6 DISASSEMBLE CAUTION: All parts must be handled carefully to avoid nicking or burring the bearing or mating surfaces. Lubricate all internal parts with clean automatic transmission fluid before assembling them. Do not use any other lubricants except on gaskets and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and seals when assembling transmission. Forward Clutch Pressure Plate Snap Ring Removal 1. Remove pressure plate snap ring. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4308 Forward Clutch Disassembled 2. Disassemble clutch. Disc Spring Replacement 3. Remove snap ring that secures disc spring in clutch cylinder and remove disc spring. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4309 Forward Clutch Piston Removal 4. Apply air pressure to clutch apply passage in cylinder to remove piston. 5. Remove seals from piston and clutch hub as shown in the Forward Clutch Assembly image. ASSEMBLE 1. Dip new seals in transmission fluid. Install smaller seal on clutch hub and the other seal on piston. 2. Install clutch piston. 3. Ensure steel pressure ring is in groove on piston. Position disc spring in cylinder with convex (dished) face downward. Install spring as shown in the Disc Spring Replacement image. Secure disc with snap ring. 4. Install forward pressure plate with flat side up and beveled side down. Dip clutch plates in transmission fluid. Install wave plate, then a steel plate and a composition driven plate. Install remaining plates in this sequence. The last plate installed will be the rear pressure plate as shown in the Forward Clutch Assembly image. NOTE: Install snap ring, making sure it is seating in the groove. If new composition plates are to be used, they should be soaked in transmission fluid for 15 minutes prior to assembly. Forward Clutch Snap Ring Clearance Inspection 5. With feeler gauge, check clearance between snap ring and pressure plate. Downward pressure on plate should be maintained when making this check. Clearance should be 0.021-0.046 inch. If not, selective thickness snap rings are available in thicknesses of 0.056-0.060 inch, 0.065-0.069 inch, 0.074-0.078 inch, 0.083-0.087 inch, 0.092-0.096 inch, 0.110-0.114 inch and 0.128-0.132 inch. Install correct thickness snap ring and recheck clearance. With E4OD DISASSEMBLE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4310 Exploded View Of Forward Clutch NOTE: Refer to the Exploded View Of Forward Clutch image when performing the following procedure. Needle Bearing Assembly Replacement 1. Remove needle bearing assembly from inner face of cylinder. 2. Remove needle bearing assembly No. 7F374. 3. Remove both Teflon seal rings No. 7F078 from grooves. 4. Remove snap ring, then the front pressure plate. 5. Remove clutch pack, cushion spring, and rear pressure plate. NOTE: Clutch pack may consist of 3 or 4 plates, depending on model. Tag parts for assembly reference. 6. Remove return spring snap ring, then the return spring. 7. Remove steel ring from piston groove. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4311 Air Application Location 8. Remove piston from cylinder using compressed air. 9. Remove outer seal from piston, then the inner seal from cylinder. ASSEMBLE NOTE: Soak all friction plates in clean transmission fluid for fifteen minutes. 1. Install inner seal in cylinder, then outer seal on piston. 2. Inspect piston check ball for freedom of movement and clean it necessary. 3. Using lip seal protector No. T77L-77548-A or equivalent, install piston into cylinder. 4. Install steel ring into groove on piston. 5. Install return spring into cylinder. Ensure return spring fingers are against piston/steel ring. 6. Install snap ring. 7. Install rear pressure plate, then cushion spring. 8. Install four steel plates and four friction plates alternately, starting with a steel plate. 9. Install selective snap ring. Using feeler gauge check stack-up. Clearance should not exceed 0.055-0.030 inch. 10. If clearance is not within specifications, install correct selective snap ring and recheck. Selective snap rings are available in following sizes: 0.056-0.060 inch, 0.074-0.078 inch, 0.092-0.096 inch, 0.110-0.114 inch and 0.128-0.132 inch. 11. Install Teflon seal rings in grooves. 12. Install needle bearing assembly No. 75374 over Teflon seal snout. 13. Install needle bearing assembly on inner face of cylinder. Ensure notched inner race is facing outward, as shown in the Needle Bearing Assembly Replacement image. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4312 Clutch: Service and Repair Intermediate Clutch Intermediate Brake Drum DISASSEMBLE 1. Remove one-way clutch outer race, then the one-way clutch assembly with end caps. 2. Remove large brass thrust washer No. 7G401 from rear face of cylinder. 3. Remove small brass thrust washer No. 7D428 from front face of cylinder. 4. Using screwdriver, remove snap ring, then the pressure plate and clutch pack. Tag parts for assembly reference. Return Spring Snap Ring Replacement 5. Remove return spring snap ring as shown in the Return Spring Snap Ring Replacement image. 6. Remove return spring assembly and piston from intermediate brake drum. 7. Remove inner and outer seals from intermediate brake drum. ASSEMBLE NOTE: Soak all friction plates in clean transmission fluid for fifteen minutes. 1. Install inner and outer seal into drum with seal groove facing down. 2. Inspect piston check ball for freedom of movement and clean as necessary. 3. Install piston and return spring assembly in drum. 4. Install return spring snap ring as shown in the Return Spring Snap Ring Replacement image. Ensure protrusions on spring retainer are properly engaged with lugs on clutch piston. 5. Install four plate clutch pack starting with steel plate. 6. Install pressure plate. 7. Install selective snap ring. Using feeler gauge, check stack-up. Clearance should not exceed 0.060-0.045 inch. 8. If clearance is not within specifications, install correct selective snap ring and recheck. Selective snap rings are available in following sizes, 0.065-0.069 inch, 0.074-0.078 inch and 0.083-0.087 inch. 9. Install small brass thrust washer No. 7D428 from front face of cylinder. 10. Install large brass thrust washer No. 7G401 from rear face of cylinder. 11. Install one-way clutch end cap, one-way clutch assembly, outer race, and outer race end cap, noting the following: a. Lip is up on one-way clutch. b. Outer race must turn counterclockwise. c. Outer race end cap is installed over inner race. Intermediate Overdrive Cylinder REMOVAL Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4313 Exploded View Of Intermediate/Overdrive Cylinder NOTE: Refer to the Exploded View Of Intermediate/Overdrive Cylinder image when performing the following procedure. Overdrive Return Spring Compression 1. Compress overdrive return spring as shown in the Overdrive Return Spring Compression image. 2. Remove snap ring, compressor tool assembly, and return spring. 3. Remove overdrive piston, outer and inner seals, and intermediate piston. 4. Remove intermediate/overdrive inner seal from cylinder bore. 5. Remove outer seal from intermediate piston. INSTALLATION 1. Reverse procedure to install, noting the following: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4314 a. Install outer seal onto intermediate piston with seal lip facing towards cylinder. b. Install intermediate/overdrive inner seal into cylinder bore with seal lip facing towards cylinder. c. Install overdrive outer and inner seals with seal lip facing towards cylinder. d. Return spring finger must be facing up. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4315 Clutch: Service and Repair Low Reverse Clutch WITH C6 REMOVAL CAUTION: All parts must be handled carefully to avoid nicking or burring the bearing or mating surfaces. Lubricate all internal parts with clean automatic transmission fluid before assembling them. Do not use any other lubricants except on gaskets and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and seals when assembling transmission. 1. Remove inner and outer seal from clutch piston. INSTALLATION 1. Dip new seals in transmission fluid and install seals on piston. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4316 Clutch: Service and Repair Coast Clutch Disassemble Exploded View Of Coast Clutch Cylinder NOTE: Refer to the Exploded View Of Coast Clutch Cylinder when performing the following procedure. 1. Remove overdrive sun gear from coast clutch cylinder. 2. Remove and discard selective snap ring. 3. Remove pressure and clutch plates from cylinder. Tag for assembly reference. 4. Using clutch spring compressor No. T65L-77515-A or equivalent, remove return spring retaining ring. 5. Remove compressor tool. 6. Remove piston return spring, piston apply plate, and piston from cylinder. 7. Remove outer seal from piston, then the inner seal from cylinder. Assemble NOTE: Soak all friction plates in clean transmission fluid for fifteen minutes. Lightly lubricate all 0-ring seals before installing, using transmission fluid. 1. Install inner seal, with lip facing down, into cylinder. 2. Install outer seal, with lip facing down, onto piston. 3. Install piston, piston apply plate, and piston return spring into cylinder. 4. Using clutch spring compressor No. T65L-7751 5-A or equivalent, install return spring retaining ring. 5. Install clutch pack plates, alternately starting with steel plate. 6. Install pressure plate. 7. Install selective snap ring. Using feeler gauge, check stack-up at 3 different points 120° apart. 8. Clearance for 2 plate is 0.052-0.027 inch and clearance for 3 plate is 0.064-0.039 inch. 9. If clearance is not within specifications, install correct selective snap ring and recheck. Selective snap rings are available in following sizes: sizes available are 0.061-0.057 inch, 0.081-0.077, 0.102-0.098, 0.122-0.118, and 0.142-0.138 inch. 10. Install overdrive sun gear, with short end of gear down, into coast clutch cylinder. Forward Carrier REMOVAL 1. Remove needle bearing assembly from carrier. 2. Remove thrust washer from front side of carrier. INSTALLATION 1. Reverse procedure to install, noting the following: a. Thrust washer tabs go into carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4317 b. Install notched inner race facing outward. Forward Hub and Ring Gear REMOVAL 1. Remove plastic thrust washer No. 7D090 from front face of hub. 2. Remove snap ring, then the forward hub from ring gear. INSTALLATION 1. Reverse procedure to install. With C6 DISASSEMBLE CAUTION: All parts must be handled carefully to avoid nicking or burring the bearing or mating surfaces. Lubricate all internal parts with clean automatic transmission fluid before assembling them. Do not use any other lubricants except on gaskets and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and seals when assembling transmission. Forward Clutch Pressure Plate Snap Ring Removal 1. Remove pressure plate snap ring. Forward Clutch Disassembled 2. Disassemble clutch. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4318 Disc Spring Replacement 3. Remove snap ring that secures disc spring in clutch cylinder and remove disc spring. Forward Clutch Piston Removal 4. Apply air pressure to clutch apply passage in cylinder to remove piston. 5. Remove seals from piston and clutch hub as shown in the Forward Clutch Assembly image. ASSEMBLE 1. Dip new seals in transmission fluid. Install smaller seal on clutch hub and the other seal on piston. 2. Install clutch piston. 3. Ensure steel pressure ring is in groove on piston. Position disc spring in cylinder with convex (dished) face downward. Install spring as shown in the Disc Spring Replacement image. Secure disc with snap ring. 4. Install forward pressure plate with flat side up and beveled side down. Dip clutch plates in transmission fluid. Install wave plate, then a steel plate and a composition driven plate. Install remaining plates in this sequence. The last plate installed will be the rear pressure plate as shown in the Forward Clutch Assembly image. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4319 NOTE: Install snap ring, making sure it is seating in the groove. If new composition plates are to be used, they should be soaked in transmission fluid for 15 minutes prior to assembly. Forward Clutch Snap Ring Clearance Inspection 5. With feeler gauge, check clearance between snap ring and pressure plate. Downward pressure on plate should be maintained when making this check. Clearance should be 0.021-0.046 inch. If not, selective thickness snap rings are available in thicknesses of 0.056-0.060 inch, 0.065-0.069 inch, 0.074-0.078 inch, 0.083-0.087 inch, 0.092-0.096 inch, 0.110-0.114 inch and 0.128-0.132 inch. Install correct thickness snap ring and recheck clearance. With E4OD DISASSEMBLE Exploded View Of Forward Clutch NOTE: Refer to the Exploded View Of Forward Clutch image when performing the following procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4320 Needle Bearing Assembly Replacement 1. Remove needle bearing assembly from inner face of cylinder. 2. Remove needle bearing assembly No. 7F374. 3. Remove both Teflon seal rings No. 7F078 from grooves. 4. Remove snap ring, then the front pressure plate. 5. Remove clutch pack, cushion spring, and rear pressure plate. NOTE: Clutch pack may consist of 3 or 4 plates, depending on model. Tag parts for assembly reference. 6. Remove return spring snap ring, then the return spring. 7. Remove steel ring from piston groove. Air Application Location 8. Remove piston from cylinder using compressed air. 9. Remove outer seal from piston, then the inner seal from cylinder. ASSEMBLE NOTE: Soak all friction plates in clean transmission fluid for fifteen minutes. 1. Install inner seal in cylinder, then outer seal on piston. 2. Inspect piston check ball for freedom of movement and clean it necessary. 3. Using lip seal protector No. T77L-77548-A or equivalent, install piston into cylinder. 4. Install steel ring into groove on piston. 5. Install return spring into cylinder. Ensure return spring fingers are against piston/steel ring. 6. Install snap ring. 7. Install rear pressure plate, then cushion spring. 8. Install four steel plates and four friction plates alternately, starting with a steel plate. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4321 9. Install selective snap ring. Using feeler gauge check stack-up. Clearance should not exceed 0.055-0.030 inch. 10. If clearance is not within specifications, install correct selective snap ring and recheck. Selective snap rings are available in following sizes: 0.056-0.060 inch, 0.074-0.078 inch, 0.092-0.096 inch, 0.110-0.114 inch and 0.128-0.132 inch. 11. Install Teflon seal rings in grooves. 12. Install needle bearing assembly No. 75374 over Teflon seal snout. 13. Install needle bearing assembly on inner face of cylinder. Ensure notched inner race is facing outward, as shown in the Needle Bearing Assembly Replacement image. Intermediate Brake Drum DISASSEMBLE 1. Remove one-way clutch outer race, then the one-way clutch assembly with end caps. 2. Remove large brass thrust washer No. 7G401 from rear face of cylinder. 3. Remove small brass thrust washer No. 7D428 from front face of cylinder. 4. Using screwdriver, remove snap ring, then the pressure plate and clutch pack. Tag parts for assembly reference. Return Spring Snap Ring Replacement 5. Remove return spring snap ring as shown in the Return Spring Snap Ring Replacement image. 6. Remove return spring assembly and piston from intermediate brake drum. 7. Remove inner and outer seals from intermediate brake drum. ASSEMBLE NOTE: Soak all friction plates in clean transmission fluid for fifteen minutes. 1. Install inner and outer seal into drum with seal groove facing down. 2. Inspect piston check ball for freedom of movement and clean as necessary. 3. Install piston and return spring assembly in drum. 4. Install return spring snap ring as shown in the Return Spring Snap Ring Replacement image. Ensure protrusions on spring retainer are properly engaged with lugs on clutch piston. 5. Install four plate clutch pack starting with steel plate. 6. Install pressure plate. 7. Install selective snap ring. Using feeler gauge, check stack-up. Clearance should not exceed 0.060-0.045 inch. 8. If clearance is not within specifications, install correct selective snap ring and recheck. Selective snap rings are available in following sizes, 0.065-0.069 inch, 0.074-0.078 inch and 0.083-0.087 inch. 9. Install small brass thrust washer No. 7D428 from front face of cylinder. 10. Install large brass thrust washer No. 7G401 from rear face of cylinder. 11. Install one-way clutch end cap, one-way clutch assembly, outer race, and outer race end cap, noting the following: a. Lip is up on one-way clutch. b. Outer race must turn counterclockwise. c. Outer race end cap is installed over inner race. Intermediate Overdrive Cylinder REMOVAL Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4322 Exploded View Of Intermediate/Overdrive Cylinder NOTE: Refer to the Exploded View Of Intermediate/Overdrive Cylinder image when performing the following procedure. Overdrive Return Spring Compression 1. Compress overdrive return spring as shown in the Overdrive Return Spring Compression image. 2. Remove snap ring, compressor tool assembly, and return spring. 3. Remove overdrive piston, outer and inner seals, and intermediate piston. 4. Remove intermediate/overdrive inner seal from cylinder bore. 5. Remove outer seal from intermediate piston. INSTALLATION 1. Reverse procedure to install, noting the following: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4323 a. Install outer seal onto intermediate piston with seal lip facing towards cylinder. b. Install intermediate/overdrive inner seal into cylinder bore with seal lip facing towards cylinder. c. Install overdrive outer and inner seals with seal lip facing towards cylinder. d. Return spring finger must be facing up. Low Reverse Clutch WITH C6 REMOVAL CAUTION: All parts must be handled carefully to avoid nicking or burring the bearing or mating surfaces. Lubricate all internal parts with clean automatic transmission fluid before assembling them. Do not use any other lubricants except on gaskets and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and seals when assembling transmission. 1. Remove inner and outer seal from clutch piston. INSTALLATION 1. Dip new seals in transmission fluid and install seals on piston. One-Way Clutch, A/T Disassemble CAUTION: All parts must be handled carefully to avoid nicking or burring the bearing or mating surfaces. Lubricate all internal parts with clean automatic transmission fluid before assembling them. Do not use any other lubricants except on gaskets and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and seals when assembling transmission. One-Way Clutch Assembly 1. Remove snap ring and bushing from rear of low reverse hub. 2. Remove rollers from spring assembly, then remove spring assembly from hub. 3. Remove remaining snap ring from hub. Assemble 1. Install snap ring in forward snap ring groove in hub, as shown in the One-Way Clutch Assembly image. 2. Position hub on bench with forward end down. 3. Install one-way clutch spring on top of snap ring. 4. Install a roller into each of spring assembly compartments. 5. Install bushing on top of spring assembly, then install snap ring. Overdrive Clutch OVERDRIVE RING GEAR AND CENTER SHAFT - WITH E4OD REMOVAL Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4324 Exploded View Of Overdrive Ring Gear And Center Shaft NOTE: Refer to the Exploded View Of Overdrive Ring Gear And Center Shaft image when performing the following procedure. 1. Remove large outer race to ring gear retaining ring, then the one-way clutch assembly with inner and outer races. 2. Push out one-way clutch assembly and inner race, then separate race from clutch assembly. 3. Remove thrust washer No. 7L339 from front of overdrive planet assembly, then remove planet assembly from center shaft and ring gear. 4. Using a screwdriver, remove needle bearing assembly No. 7F240 from rear face of overdrive planet assembly. 5. Remove center shaft to ring gear wave-type snap ring, then the center shaft from ring gear. INSTALLATION 1. Reverse procedure to install, noting the following: a. Outer race assembly snap ring groove must be facing up. One-Way Clutch Installation b. One-way clutch must be installed as shown in the Exploded View Of Overdrive Ring Gear And Center Shaft image and the One-Way Clutch Installation image. c. Inner race must rotate counterclockwise from direction of installation. Removal and Installation REVERSE ONE-WAY CLUTCH - WITH E4OD REMOVAL 1. Remove reverse hub and needle bearing assembly from reverse one-way clutch hub. 2. Remove snap ring from reverse one-way clutch hub. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4325 3. Remove brass thrust washer and rollers from reverse clutch hub. INSTALLATION 1. Reverse procedure to install. Disassembly and Assembly DISASSEMBLE CAUTION: All parts must be handled carefully to avoid nicking or burring the bearing or mating surfaces. Lubricate all internal parts with clean automatic transmission fluid before assembling them. Do not use any other lubricants except on gaskets and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and seals when assembling transmission. Drivetrain Assembly 1. Separate drive train as shown in the Drivetrain Assembly image. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4326 Reverse-high Clutch Pressure Plate Snap Ring Removal 2. Remove pressure plate snap ring from clutch. 3. Remove clutch parts. Reverse-High Clutch Piston Snap Ring Removal 4. Install tool shown in the Reverse-High Clutch Piston Snap Ring Removal image or its equivalent on clutch drum. Ensure legs clear snap ring enough to permit expanding it for its removal. Remove tool after snap ring has been removed. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4327 Reverse-High Clutch Disassembled 5. Remove spring retainer and piston return springs. Reverse-High Clutch Piston Removal 6. Apply air pressure to piston apply hole in clutch hub and remove piston. 7. Remove piston outer seal from piston and inner seal from clutch drum. Bushing Replacement Reverse-High Clutch Rear Bushing Removal 1. To replace the rear bushing, position the clutch housing in a press and remove the bushing as shown in the Reverse-High Clutch Rear Bushing Removal image. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4328 2. To remove the front bushing, use a cape chisel and cut along the bushing seam until the chisel breaks through the bushing wall. Pry the loose bushing ends up and remove the bushing. Reverse-High Clutch Front Bushing Installation 3. To install the front bushing, press it into the housing as shown in the Reverse-High Clutch Front Bushing Installation image. ASSEMBLE 1. Dip new seals in transmission fluid and install one on drum and one on piston. Install piston in clutch drum. 2. Place return springs in piston pockets. Place retainer on springs. NOTE: Return springs must be placed in sockets. 3. Compress springs with tool shown in the Reverse-High Clutch Piston Snap Ring Removal image. Make certain that spring retainer is centered while compressing springs. Install snap ring. Before releasing pressure on tool, see that snap ring is positioned inside four snap ring guides on spring retainer. 4. Dip clutch plates in transmission fluid. Install clutch plates alternately starting with a steel drive plate and a composition plate, as shown in the Reverse-High Clutch Assembly image. NOTE: If new composition plates are to be used, they should be soaked in transmission fluid for 15 minutes prior to assembly. 5. After all the clutch plates have been installed, position pressure plate in clutch drum. Install pressure plate snap ring. Reverse-High Clutch Snap Ring Clearance Inspection Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 4329 6. With feeler gauge, check clearance between pressure plate and snap ring. Pressure plate should be held down as clearance is checked. Clearance should be 0.022-0.036 inch. If clearance is not within specifications, selective thickness snap rings are available in thicknesses of 0.056-0.060 inch, 0.065-0.069 inch, 0.074-0.078 inch, 0.083-0.087 inch, 0.092-0.096 inch, 0.110-0.114 inch and 0.128-0.132 inch. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation Power Control Module (PCM). Description The operation of the E4OD automatic transmission is controlled by the PCM. Many input sensors provide information to the PCM, which then controls the actuators which affect transmission operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > With C6 Extension Housing: Service and Repair With C6 REMOVAL 1. Raise and support vehicle. 2. Disconnect drive shaft from rear axle flange and remove from transmission. 3. On 4WD models, remove transfer case. 4. On all models, disconnect speedometer cable from extension housing, if equipped. 5. Remove engine rear support and insulator assembly to extension housing attaching bolts. 6. Raise transmission with a transmission jack just high enough to relieve weight from rear engine support. 7. Remove bolts that secure engine rear support to crossmember, then remove support. 8. Place drain pan under rear of transmission case. 9. Lower transmission to permit access to extension housing bolts. Remove bolts and slide housing off output shaft. 10. Remove four (4) governor body to oil collector attaching bolts and slide governor off output shaft. INSTALLATION 1. Install governor to distributor flange, then torque bolts to 7-10 ft lbs. 2. Position new gasket on transmission. 3. Install extension housing to case, then torque bolts to 25-35 ft lbs. 4. Raise transmission to position engine rear support on crossmember. 5. Install engine rear support to case, then torque bolts to 6O-80 ft lbs. 6. Lower transmission and remove jack. Install and torque engine rear support to extension housing bolts to 40-60 ft lbs. 7. Install speedometer cable, then install drive shaft. 8. On 4WD models, install transfer case. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > With C6 > Page 4337 Extension Housing: Service and Repair With E4OD REMOVAL 1. Raise and support vehicle. 2. On 4WD models, remove front and rear driveshafts. 3. On 2WD models, remove rear driveshaft. 4. On all models, remove transmission mounting pad attaching nuts and bolts. 5. On 4WD models, remove transfer case shift linkage to shift lever. 6. On 4WD models, remove four-wheel drive switch connector from transfer case. Do not overextend tabs. 7. On all models, pry wire harness locator from extension housing wire bracket. 8. On 4WD models, disconnect wire harness locators from left side of crossmember. 9. On all models, remove speedometer cable. 10. On 4WD models, remove transfer case vent hose. 11. On 4WD models, position a suitable jack under transfer case. 12. On 2WD models, remove nine bolts securing extension housing, then remove extension housing. 13. On 4WD models, remove nine bolts securing extension housing, then slide transfer case to gain clearance and remove housing. INSTALLATION 1. On all models, reverse procedure to install, noting the following: a. Refer to Technical Service Bulletins (TSB) for related information. b. On 2WD models, torque extension housing bolts to 20-29 ft lbs. c. On 4WD models, torque extension housing bolts to 24-40 ft lbs. d. Torque mounting pad bolts to 60-80 ft lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration Fluid - A/T: Customer Interest A/T - Vibration/Shudder On Light Acceleration Article No. 95-23-4 11/20/95 FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to clarify Issue, Action, Service Procedure, and Operation. ISSUE: Torque converter clutch shudder or vibration may occur under light to moderate acceleration above 56 km/h (35 mph) while in 3rd or 4th gear or during 3-4 or 4-3 shifts. This condition may be noticeable on higher mileage vehicles (24,000 km/15,000 mi or more) when the torque converter clutch engages or disengages during light to moderate acceleration. ACTION: Perform normal diagnostics (i.e., linkage adjustment fluid level and condition, On-Board diagnostic check). If self test codes are present, service as required. If no DTCs are present, perform the following Service Procedure. SERVICE PROCEDURE 1. Drain all transmission fluid. Refer to the appropriate Service Manual, Section 07-01 for details. If fluid is burnt or heavily contaminated, repair as required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 4346 2. Remove transmission and replace the torque converter assembly with the correct torque converter. Refer to Figure 1. 3. Remove the transmission pan and clean transmission pan and pan magnet. 4. Inspect transmission pan gasket and filter. Reuse both pan gasket and filter if not damaged. 5. Reinstall filter, pan magnet, and transmission pan with original gasket. 6. Completely clean and flush transmission cooler and cooler lines. 7. Reinstall the transmission assembly. 8. Refill transmission with Mercon(R) Automatic Transmission Fluid (XT-2-QDX). Use only quart containers of Mercon(R) when refilling to ensure proper fluid quality is being used. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 4347 PART NUMBER PART NAME XT-2-QDX Mercon(R) Automatic Transmission Fluid F5AZ-7902-ARM Torque Converter F5ZZ-7902-ARM Torque Converter F4LY-7902-ARM Torque Converter F4SZ-7902-BRM Torque Converter Please use the following repair description for each model described in the OPERATION/DESCRIPTION/TIME section of this TSB article: Perform electronic transmission diagnostics, replace torque converter, drain and fill transmission (including inspection of filter - replace if necessary), flush cooler and lines. Road test vehicle after repairs are complete. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-14-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952304A 1994-95 Econoline 4.6 Hrs. 952304B 1994-95 F-Series 4X2 4.4 Hrs. 952304C 1994-95 F-Series 4X4 6.0 Hrs. 952304D 1994-95 Mustang 3.8L 5.1 Hrs. 952304E 1994-95 Mustang 5.0L 5.3 Hrs. 952304F 1994-95 5.4 Hrs. Thunderbird/Cougar 4.6L 952304G 1994-95 5.3 Hrs. Thunderbird/Cougar 3.8L 952304H 1993-95 Mark VIII 5.4 Hrs. 952304I 1992-95 Crown 4.9 Hrs. Victoria/Grand Marquis/Town Car DEALER CODING CONDITION BASIC PART NO. CODE 7902 67 OASIS CODES: 501000, 502000, 504000, 510000, 597997, 703000, 703200, 703400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 4353 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 4354 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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: > 95234 > Nov > 95 > A/T Vibration/Shudder On Light Acceleration Fluid - A/T: All Technical Service Bulletins A/T - Vibration/Shudder On Light Acceleration Article No. 95-23-4 11/20/95 FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to clarify Issue, Action, Service Procedure, and Operation. ISSUE: Torque converter clutch shudder or vibration may occur under light to moderate acceleration above 56 km/h (35 mph) while in 3rd or 4th gear or during 3-4 or 4-3 shifts. This condition may be noticeable on higher mileage vehicles (24,000 km/15,000 mi or more) when the torque converter clutch engages or disengages during light to moderate acceleration. ACTION: Perform normal diagnostics (i.e., linkage adjustment fluid level and condition, On-Board diagnostic check). If self test codes are present, service as required. If no DTCs are present, perform the following Service Procedure. SERVICE PROCEDURE 1. Drain all transmission fluid. Refer to the appropriate Service Manual, Section 07-01 for details. If fluid is burnt or heavily contaminated, repair as required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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: > 95234 > Nov > 95 > A/T Vibration/Shudder On Light Acceleration > Page 4359 2. Remove transmission and replace the torque converter assembly with the correct torque converter. Refer to Figure 1. 3. Remove the transmission pan and clean transmission pan and pan magnet. 4. Inspect transmission pan gasket and filter. Reuse both pan gasket and filter if not damaged. 5. Reinstall filter, pan magnet, and transmission pan with original gasket. 6. Completely clean and flush transmission cooler and cooler lines. 7. Reinstall the transmission assembly. 8. Refill transmission with Mercon(R) Automatic Transmission Fluid (XT-2-QDX). Use only quart containers of Mercon(R) when refilling to ensure proper fluid quality is being used. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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: > 95234 > Nov > 95 > A/T Vibration/Shudder On Light Acceleration > Page 4360 PART NUMBER PART NAME XT-2-QDX Mercon(R) Automatic Transmission Fluid F5AZ-7902-ARM Torque Converter F5ZZ-7902-ARM Torque Converter F4LY-7902-ARM Torque Converter F4SZ-7902-BRM Torque Converter Please use the following repair description for each model described in the OPERATION/DESCRIPTION/TIME section of this TSB article: Perform electronic transmission diagnostics, replace torque converter, drain and fill transmission (including inspection of filter - replace if necessary), flush cooler and lines. Road test vehicle after repairs are complete. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-14-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952304A 1994-95 Econoline 4.6 Hrs. 952304B 1994-95 F-Series 4X2 4.4 Hrs. 952304C 1994-95 F-Series 4X4 6.0 Hrs. 952304D 1994-95 Mustang 3.8L 5.1 Hrs. 952304E 1994-95 Mustang 5.0L 5.3 Hrs. 952304F 1994-95 5.4 Hrs. Thunderbird/Cougar 4.6L 952304G 1994-95 5.3 Hrs. Thunderbird/Cougar 3.8L 952304H 1993-95 Mark VIII 5.4 Hrs. 952304I 1992-95 Crown 4.9 Hrs. Victoria/Grand Marquis/Town Car DEALER CODING CONDITION BASIC PART NO. CODE 7902 67 OASIS CODES: 501000, 502000, 504000, 510000, 597997, 703000, 703200, 703400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 4366 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 4367 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications TYPE MA CAPACITY, Initial Refill*: C-6 (deep pan) 6.0 qt (US) C-6 (shallow pan) 5.0 qt (US) E4OD: W/4x2 15.7 qt (US) W/4x4 16.2 qt (US) 4R70W: W/4x2 13.6 qt (US) W/4x4 14.6 qt (US) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4370 Fluid - A/T: Fluid Type Specifications Fluid Type ............................................................................................................................................ ............................................... MERCON(R) V ATF Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > With C6 Fluid - A/T: Testing and Inspection With C6 FLUID CHECK 1. Make sure car is on a level floor. 2. Apply parking brake firmly. 3. Run engine at normal idle speed. If transmission fluid is cold, run engine at a fast idle until fluid reaches normal operating temperature. When fluid is warm, slow engine to normal idle speed. 4. Shift selector lever through all positions, then place lever at Park. Do not shut down engine during fluid level checks. 5. Clean all dirt from dipstick cap before removing dipstick from filler tube. 6. Pull dipstick out of tube, wipe it clean, and push it all the way back in tube. 7. Pull dipstick out of tube again and check fluid level. If necessary, add specified fluid to raise the level to the Full mark on dipstick. Do not overfill. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > With C6 > Page 4373 Fluid - A/T: Testing and Inspection With E4OD FLUID CHECK NOTE: The automatic transmission is designed to operate with the fluid level between the Add and Full mark on the dipstick at an operating temperature of 150° F - 170° F. 1. With transmission in Park, engine at curb idle RPM, foot brake applied, and vehicle on level surface, move transmission selector lever through each range. 2. Allow time in each range to engage transmission, then return selector to Park. 3. Apply parking brake. NOTE: Do not turn off engine during the fluid level check. 4. Remove dipstick from filler tube, wipe clean, and push dipstick back into tube. Ensure it is fully seated. 5. Remove dipstick from filler tube and check fluid level. Fluid level should be between Add and Full mark. 6. If necessary, add enough fluid through filler tube to raise level to correct position. NOTE: Do not overfill. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > With C6 Fluid - A/T: Service and Repair With C6 FLUID CHANGE NOTE: Normal maintenance and lubrication requirements do not necessitate periodic fluid changes. If a major failure has occurred in the transmission, it will have to be removed for service. At this time the converter must be thoroughly flushed to remove any foreign matter. CAUTION: Use of a fluid other than specified could result in transmission malfunction and failure. 1. To drain the fluid, loosen pan attaching bolts and allow fluid to drain. 2. After fluid has drained to the level of the pan flange, remove pan bolts working from rear and both sides of pan to allow it to drop and drain slowly. 3. When fluid has stopped draining, remove and clean pan and screen. Discard pan gasket. 4. Using a new gasket, install pan. 5. Add recommended fluid to transmission through filler tube. 6. Run engine at idle speed for 2 minutes, and then run it at a fast idle until it reaches normal operating temperature. 7. Shift selector lever through all positions, place it at Park and check fluid level. 8. If necessary, add enough fluid to transmission to bring it to the Full mark on the dipstick. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > With C6 > Page 4376 Fluid - A/T: Service and Repair With E4OD FLUID CHANGE NOTE: No service is required on this transmission under normal use. If any of the following driving conditions exist, the transmission fluid, filter, and gasket should be changed every 21,000 miles: Sustained high speed driving at or above 90° F, towing a trailer for more than 1,000 miles, accumulating more than 5,000 miles per month or continuous running service. If service is needed proceed as follows: 1. Loosen transmission fluid pan bolts to partially drain fluid. 2. Slowly remove remaining bolts, lower pan and discard old gasket. 3. Drain torque converter by removing drain plug. 4. Reverse procedure to install, noting the following: a. Install new torque converter drain plug and torque to 18-20 ft lbs. b. Ensure the new filter and gasket application is correct. CAUTION: 4WD and 2WD are not interchangeable. Damage may result if wrong filter is installed. c. Only use MERCON transmission fluid. d. Install pan bolts and torque to 10-12 ft lbs. e. Add 6 1/2 quarts of MERCON(R) V transmission fluid. f. Check fluid and add as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration Fluid Filter - A/T: Customer Interest A/T - Vibration/Shudder On Light Acceleration Article No. 95-23-4 11/20/95 FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to clarify Issue, Action, Service Procedure, and Operation. ISSUE: Torque converter clutch shudder or vibration may occur under light to moderate acceleration above 56 km/h (35 mph) while in 3rd or 4th gear or during 3-4 or 4-3 shifts. This condition may be noticeable on higher mileage vehicles (24,000 km/15,000 mi or more) when the torque converter clutch engages or disengages during light to moderate acceleration. ACTION: Perform normal diagnostics (i.e., linkage adjustment fluid level and condition, On-Board diagnostic check). If self test codes are present, service as required. If no DTCs are present, perform the following Service Procedure. SERVICE PROCEDURE 1. Drain all transmission fluid. Refer to the appropriate Service Manual, Section 07-01 for details. If fluid is burnt or heavily contaminated, repair as required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 4385 2. Remove transmission and replace the torque converter assembly with the correct torque converter. Refer to Figure 1. 3. Remove the transmission pan and clean transmission pan and pan magnet. 4. Inspect transmission pan gasket and filter. Reuse both pan gasket and filter if not damaged. 5. Reinstall filter, pan magnet, and transmission pan with original gasket. 6. Completely clean and flush transmission cooler and cooler lines. 7. Reinstall the transmission assembly. 8. Refill transmission with Mercon(R) Automatic Transmission Fluid (XT-2-QDX). Use only quart containers of Mercon(R) when refilling to ensure proper fluid quality is being used. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 4386 PART NUMBER PART NAME XT-2-QDX Mercon(R) Automatic Transmission Fluid F5AZ-7902-ARM Torque Converter F5ZZ-7902-ARM Torque Converter F4LY-7902-ARM Torque Converter F4SZ-7902-BRM Torque Converter Please use the following repair description for each model described in the OPERATION/DESCRIPTION/TIME section of this TSB article: Perform electronic transmission diagnostics, replace torque converter, drain and fill transmission (including inspection of filter - replace if necessary), flush cooler and lines. Road test vehicle after repairs are complete. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-14-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952304A 1994-95 Econoline 4.6 Hrs. 952304B 1994-95 F-Series 4X2 4.4 Hrs. 952304C 1994-95 F-Series 4X4 6.0 Hrs. 952304D 1994-95 Mustang 3.8L 5.1 Hrs. 952304E 1994-95 Mustang 5.0L 5.3 Hrs. 952304F 1994-95 5.4 Hrs. Thunderbird/Cougar 4.6L 952304G 1994-95 5.3 Hrs. Thunderbird/Cougar 3.8L 952304H 1993-95 Mark VIII 5.4 Hrs. 952304I 1992-95 Crown 4.9 Hrs. Victoria/Grand Marquis/Town Car DEALER CODING CONDITION BASIC PART NO. CODE 7902 67 OASIS CODES: 501000, 502000, 504000, 510000, 597997, 703000, 703200, 703400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration Fluid Filter - A/T: All Technical Service Bulletins A/T - Vibration/Shudder On Light Acceleration Article No. 95-23-4 11/20/95 FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to clarify Issue, Action, Service Procedure, and Operation. ISSUE: Torque converter clutch shudder or vibration may occur under light to moderate acceleration above 56 km/h (35 mph) while in 3rd or 4th gear or during 3-4 or 4-3 shifts. This condition may be noticeable on higher mileage vehicles (24,000 km/15,000 mi or more) when the torque converter clutch engages or disengages during light to moderate acceleration. ACTION: Perform normal diagnostics (i.e., linkage adjustment fluid level and condition, On-Board diagnostic check). If self test codes are present, service as required. If no DTCs are present, perform the following Service Procedure. SERVICE PROCEDURE 1. Drain all transmission fluid. Refer to the appropriate Service Manual, Section 07-01 for details. If fluid is burnt or heavily contaminated, repair as required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 4392 2. Remove transmission and replace the torque converter assembly with the correct torque converter. Refer to Figure 1. 3. Remove the transmission pan and clean transmission pan and pan magnet. 4. Inspect transmission pan gasket and filter. Reuse both pan gasket and filter if not damaged. 5. Reinstall filter, pan magnet, and transmission pan with original gasket. 6. Completely clean and flush transmission cooler and cooler lines. 7. Reinstall the transmission assembly. 8. Refill transmission with Mercon(R) Automatic Transmission Fluid (XT-2-QDX). Use only quart containers of Mercon(R) when refilling to ensure proper fluid quality is being used. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 4393 PART NUMBER PART NAME XT-2-QDX Mercon(R) Automatic Transmission Fluid F5AZ-7902-ARM Torque Converter F5ZZ-7902-ARM Torque Converter F4LY-7902-ARM Torque Converter F4SZ-7902-BRM Torque Converter Please use the following repair description for each model described in the OPERATION/DESCRIPTION/TIME section of this TSB article: Perform electronic transmission diagnostics, replace torque converter, drain and fill transmission (including inspection of filter - replace if necessary), flush cooler and lines. Road test vehicle after repairs are complete. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-14-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952304A 1994-95 Econoline 4.6 Hrs. 952304B 1994-95 F-Series 4X2 4.4 Hrs. 952304C 1994-95 F-Series 4X4 6.0 Hrs. 952304D 1994-95 Mustang 3.8L 5.1 Hrs. 952304E 1994-95 Mustang 5.0L 5.3 Hrs. 952304F 1994-95 5.4 Hrs. Thunderbird/Cougar 4.6L 952304G 1994-95 5.3 Hrs. Thunderbird/Cougar 3.8L 952304H 1993-95 Mark VIII 5.4 Hrs. 952304I 1992-95 Crown 4.9 Hrs. Victoria/Grand Marquis/Town Car DEALER CODING CONDITION BASIC PART NO. CODE 7902 67 OASIS CODES: 501000, 502000, 504000, 510000, 597997, 703000, 703200, 703400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 9584 > Apr > 95 > A/T - AODE/4R70W Reusable Pan Gasket/Filter Fluid Filter - A/T: All Technical Service Bulletins A/T - AODE/4R70W Reusable Pan Gasket/Filter Article No. 95-8-4 04/24/95 ^ LEAKS - AODE/4R70W - REUSABLE PAN GASKET AND FILTER ^ TRANSMISSION - AODE/4R70W - REUSABLE PAN GASKET AND FILTER - SERVICE TIP FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to advise of updated information. ISSUE: The AODE/4R70W transmission pan gaskets and filter may be reusable. ACTION: Refer to the following to determine if the transmission pan gasket and/or filter should be reused. The AODE/4R7OW transmission pan gasket has been designed to be reusable if it is removed for a non-leak related transmission service. The gasket should be inspected for damage and cleaned, along with the mating surfaces, before reuse. If the gasket requires replacement, retain the original gasket per the parts retention and return procedures as outlined in the Warranty and Policy Manual. NOTE: THE PAN GASKET IS NOT INCLUDED IN THE GASKET AND SEAL KIT. IT CAN ONLY BE ORDERED SEPARATELY. The transmission fluid filter has also been designed to be reuseable if removed from a transmission which did not have any component failure. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-19-12 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000, 510000, 590000, 597997 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 9584 > Apr > 95 > A/T - AODE/4R70W Reusable Pan Gasket/Filter Fluid Filter - A/T: All Technical Service Bulletins A/T - AODE/4R70W Reusable Pan Gasket/Filter Article No. 95-8-4 04/24/95 ^ LEAKS - AODE/4R70W - REUSABLE PAN GASKET AND FILTER ^ TRANSMISSION - AODE/4R70W - REUSABLE PAN GASKET AND FILTER - SERVICE TIP FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to advise of updated information. ISSUE: The AODE/4R70W transmission pan gaskets and filter may be reusable. ACTION: Refer to the following to determine if the transmission pan gasket and/or filter should be reused. The AODE/4R7OW transmission pan gasket has been designed to be reusable if it is removed for a non-leak related transmission service. The gasket should be inspected for damage and cleaned, along with the mating surfaces, before reuse. If the gasket requires replacement, retain the original gasket per the parts retention and return procedures as outlined in the Warranty and Policy Manual. NOTE: THE PAN GASKET IS NOT INCLUDED IN THE GASKET AND SEAL KIT. IT CAN ONLY BE ORDERED SEPARATELY. The transmission fluid filter has also been designed to be reuseable if removed from a transmission which did not have any component failure. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-19-12 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000, 510000, 590000, 597997 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4407 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4408 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Application and ID > With C6 Ford C6 Transmission Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Application and ID > With C6 > Page 4413 Ford E4OD Transmission Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 95219 > Oct > 95 > A/T - E4OD Planetary Gearset Heat Distress Fluid Pump: Customer Interest A/T - E4OD Planetary Gearset Heat Distress ARTICLE NO. 95-21-9 10/23/95 TRANSMISSION - E4OD - HEAT STAINED OVERDRIVE PLANETARY GEARSET, COAST CLUTCH CYLINDER BUSHING AND/OR OVERDRIVE CYLINDER BUSHING LIGHT TRUCK: 1995 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES This TSB is being republished in its entirety to correct the transmission build dates. ISSUE: Some E4OD transmissions with build dates between 5803 (February 3, 1995) and 5E31 (May 31, 1995) may have a valve, in the pump, that restricts fluid flow (Figure 1). This valve may become stuck in the valve bore and restrict lubrication. Symptoms may include heat distress on the overdrive planetary gearset, coast clutch cylinder bushing and/or overdrive cylinder bushing. ACTION: During overhaul of E4OD transmissions with build dates 5B03 and 5E31, inspect the components listed above for signs of heat distress. Replace the valve assembly using a service valve kit (E9TQ-7H132-B) which should resolve the issue. Refer to the Instruction Sheet included in the kit for details. The Valve Kit includes the following: ^ One (1) Orifice Cup Plug ^ One (1) Spring and Stop Assembly ^ One (1) Instruction Sheet (I.S. # 6574) PART NUMBER PART NAME E9TZ-7H132-B Valve Kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-19-14 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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: > 97-19-20 > Sep > 97 > A/T - E4OD Main Regulator Booster Service Tip Fluid Pump: All Technical Service Bulletins A/T - E4OD Main Regulator Booster Service Tip Article No. 97-19-20 09/15/97 TRANSMISSION - E4OD - MAIN REGULATOR BOOSTER VALVE AND SLEEVE SERVICE KIT SERVICE TIP LIGHT TRUCK: 1989-96 BRONCO 1989-97 ECONOLINE, F-150-350 SERIES, F-53 MOTORHOME CHASSIS 1997-98 EXPEDITION 1998 NAVIGATOR ISSUE: An E4OD Transmission Main Regulator Booster Valve and Sleeve Service kit has been released for service. ACTION: When servicing an E4OD transmission, inspect the main regulator booster valve and sleeve assembly for signs of wear. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the pump is disassembled, cleaned and inspected before using this kit. 2. Refer to the appropriate Service/Workshop Manual for proper disassembly, cleaning and inspection procedures for the pump and service as required. 3. Inspect the main regulator booster valve and sleeve assembly. If the valve and sleeve show signs of wear, install kit. CAUTION: IF THE PUMP BORE THAT HOLDS THE MAIN MAIN REGULATOR BOOSTER VALVE AND SLEEVE ASSEMBLY IS DAMAGED, DO NOT USE THIS Km REPLACE THE PUMP. 4. Refer to Figure 1 for the location of the valve and sleeve. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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: > 97-19-20 > Sep > 97 > A/T - E4OD Main Regulator Booster Service Tip > Page 4427 5. Refer to Figure 2 for orientation of the valve and sleeve in the pump. The Main Regulator Booster Valve and Sleeve kit (E9TZ-7D003-AA) contains the following: ^ One (1) Main Regulator Booster Valve ^ One (1) Main Regulator Booster Valve Sleeve ^ One (1) Instruction Sheet (I.S. 7277) PART NUMBER PART NAME E9TZ-7DO03-AA Sleeve Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000, 590000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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: > 95219 > Oct > 95 > A/T - E4OD Planetary Gearset Heat Distress Fluid Pump: All Technical Service Bulletins A/T - E4OD Planetary Gearset Heat Distress ARTICLE NO. 95-21-9 10/23/95 TRANSMISSION - E4OD - HEAT STAINED OVERDRIVE PLANETARY GEARSET, COAST CLUTCH CYLINDER BUSHING AND/OR OVERDRIVE CYLINDER BUSHING LIGHT TRUCK: 1995 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES This TSB is being republished in its entirety to correct the transmission build dates. ISSUE: Some E4OD transmissions with build dates between 5803 (February 3, 1995) and 5E31 (May 31, 1995) may have a valve, in the pump, that restricts fluid flow (Figure 1). This valve may become stuck in the valve bore and restrict lubrication. Symptoms may include heat distress on the overdrive planetary gearset, coast clutch cylinder bushing and/or overdrive cylinder bushing. ACTION: During overhaul of E4OD transmissions with build dates 5B03 and 5E31, inspect the components listed above for signs of heat distress. Replace the valve assembly using a service valve kit (E9TQ-7H132-B) which should resolve the issue. Refer to the Instruction Sheet included in the kit for details. The Valve Kit includes the following: ^ One (1) Orifice Cup Plug ^ One (1) Spring and Stop Assembly ^ One (1) Instruction Sheet (I.S. # 6574) PART NUMBER PART NAME E9TZ-7H132-B Valve Kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-19-14 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 97-19-20 > Sep > 97 > A/T - E4OD Main Regulator Booster Service Tip Fluid Pump: All Technical Service Bulletins A/T - E4OD Main Regulator Booster Service Tip Article No. 97-19-20 09/15/97 TRANSMISSION - E4OD - MAIN REGULATOR BOOSTER VALVE AND SLEEVE SERVICE KIT SERVICE TIP LIGHT TRUCK: 1989-96 BRONCO 1989-97 ECONOLINE, F-150-350 SERIES, F-53 MOTORHOME CHASSIS 1997-98 EXPEDITION 1998 NAVIGATOR ISSUE: An E4OD Transmission Main Regulator Booster Valve and Sleeve Service kit has been released for service. ACTION: When servicing an E4OD transmission, inspect the main regulator booster valve and sleeve assembly for signs of wear. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the pump is disassembled, cleaned and inspected before using this kit. 2. Refer to the appropriate Service/Workshop Manual for proper disassembly, cleaning and inspection procedures for the pump and service as required. 3. Inspect the main regulator booster valve and sleeve assembly. If the valve and sleeve show signs of wear, install kit. CAUTION: IF THE PUMP BORE THAT HOLDS THE MAIN MAIN REGULATOR BOOSTER VALVE AND SLEEVE ASSEMBLY IS DAMAGED, DO NOT USE THIS Km REPLACE THE PUMP. 4. Refer to Figure 1 for the location of the valve and sleeve. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 97-19-20 > Sep > 97 > A/T - E4OD Main Regulator Booster Service Tip > Page 4437 5. Refer to Figure 2 for orientation of the valve and sleeve in the pump. The Main Regulator Booster Valve and Sleeve kit (E9TZ-7D003-AA) contains the following: ^ One (1) Main Regulator Booster Valve ^ One (1) Main Regulator Booster Valve Sleeve ^ One (1) Instruction Sheet (I.S. 7277) PART NUMBER PART NAME E9TZ-7DO03-AA Sleeve Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000, 590000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4438 Fluid Pump: Description and Operation DESCRIPTION AND OPERATION The pump provides a supply of transmission fluid under pressure to operate, lubricate, and cool the transmission. The center support provides a flow path for fluid to activate the forward and direct clutches and lubricate the intermediate circuit. The center support also acts as a pilot for the intermediate brake drum. The intermediate/overdrive cylinder provides a fluid path to activate the intermediate and overdrive clutches. The intermediate servo applies the band in manual two. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4439 Fluid Pump: Testing and Inspection INSPECTION Exploded View Of Front Pump NOTE: Refer to the Exploded View Of Front Pump image when performing the following procedure. 1. Inspect all components for damage or scoring. Replace entire pump if any part is damaged or worn. 2. Inspect converter hub bushing, then replace if scored or worn. Stake bushing at notches. 3. Inspect converter hub seal. If damaged, remove with impact slide hammer and seal remover No. 1175-AC or equivalent. Install new seal with seal installer No. T63L-77837-A or equivalent. 4. Inspect stator input shaft bushings. If bushings are worn or scored, replace complete control body assembly. 5. Inspect all valve and plug bores for scoring and check all passages for obstructions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4440 6. Inspect mating surfaces for burrs and scoring. If necessary, use crocus cloth to polish components. Use caution to avoid rounding sharp edges of valves and plugs. 7. Inspect all springs for distortion. Ensure all valves and plugs fall freely from their bores. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > With C6 Fluid Pump: Service and Repair With C6 DISASSEMBLE CAUTION: All parts must be handled carefully to avoid nicking or burring the bearing or mating surfaces. Lubricate all internal parts with clean automatic transmission fluid before assembling them. Do not use any other lubricants except on gaskets and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and seals when assembling transmission. Removing Front Pump Seal Installing Front Pump Seal NOTE: The front seal can be replaced after the pump has been installed on the transmission, as shown in the Front Pump Seal Replacement and the Front Pump Seal Installation images. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > With C6 > Page 4443 Front Pump Disassembled 1. To disassemble the pump, refer to the Front Pump Assembly image, and remove two seal rings and selective thrust washer. 2. Remove square-cut seal from pump housing outside diameter. 3. Unfasten and remove support from pump housing (5 bolts). 4. Remove drive and driven gear from housing. 5. If pump housing bushing is worn or damaged, it must be replaced. 6. If new bushing is replaced, ensure half moon slot in bushing is on top and in line with oil lube hole. ASSEMBLE 1. Install drive and driven gears in housing. Each gear has an identification mark on one face. The mark on each gear must be toward front of pump housing. 2. Position stator support in housing and secure with five bolts. 3. Carefully install two new seal rings in stator support. Ensure ring ends are engaged to lock them in place. Install new square-cut seal on pump housing outside diameter. 4. Install selective thrust washer of the proper thickness to provide gear train endplay of 0.008-0.044 inch, as measured with the dial indicator prior to disassembly of transmission. 5. Place pump on converter, making sure that drive gear engages converter hub. Rotate pump to make sure that gears rotate freely. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > With C6 > Page 4444 Fluid Pump: Service and Repair With E4OD DISASSEMBLE Exploded View Of Front Pump NOTE: Refer to the Exploded View Of Front Pump image when performing the following procedure. 1. Remove torque converter clutch seal from front of stator support. 2. Remove Teflon coast clutch seals from stator support, then the converter clutch seal from front of stator support. 3. Remove pump outer diameter square cut seal. 4. Remove eleven retaining bolts and separate pump control body and pump body. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > With C6 > Page 4445 NOTE: Do not remove any cup plugs. 5. Remove main regulator valve internal snap ring, then the valve assembly. 6. Remove converter regulator valve retaining clip, then the valve assembly. 7. Remove converter clutch shift valve retaining clip, then the valve assembly. 8. Remove gerotor gear set from pump body. ASSEMBLE 1. Install main regulator valve assembly, converter regulator valve assembly, and converter clutch shift valve assembly as shown in the Exploded View Of Front Pump image. 2. Lubricate and install gerotor gears into pump housing. NOTE: Dot on inner gerotor gear must face the control body assembly. 28 MM Hole Location 3. Lower control body and stator assembly onto pump body. Align 28 mm round hole in control body with 28 mm hole in pump body. 4. Loosely install eleven retaining bolts into pump body. 5. Install banding tool No. D89L-77000-A or equivalent with clamp by filter inlet. 6. Align outer bolt holes and tighten banding tool. This aligns input shaft bushings to the converter hub bushings. Installing Coast Clutch Seals 7. Install coast clutch Teflon seals, then the converter lock-up seal on front of stator support. 8. Lubricate and install pump outer diameter seal. Ensure groove is clean and free of burrs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation Governor: Description and Operation DESCRIPTION AND OPERATION The governor operation is the same as earlier models except that when the secondary governor valve is regulating, governor pressure is delivered to the 3-2 timing valve, 2-3 shift valve, 1-2 shift valve, coasting boost valve, and cut back valve. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Page 4449 Governor: Testing and Inspection GOVERNOR TEST NOTE: The governor can be checked at the same time the Control Pressure Test is performed. To do so, proceed as follows: 1. Raise and support vehicle. 2. With no load on engine, place transmission in Drive and apply 10 in Hg of vacuum to vacuum diaphragm. 3. Record speed at which control pressure cutback occurs. 4. Cutback should occur between 10-20 mph. Replace governor as needed. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Description and Operation > Page 4450 Governor: Service and Repair AOD-E / AODE-W (4R70W) REMOVAL & INSTALLATION 1. Remove extension housing. If governor body only is being removed, proceed to step 4. 2. Remove governor to output shaft retaining snap ring. 3. Remove governor assembly from output shaft using suitable tool. Remove governor drive ball. 4. Remove governor to counterweight retaining screws. Remove governor from counterweight. 5. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T > Component Information > Description and Operation Input Shaft: Description and Operation WITH A4OD DESCRIPTION AND OPERATION The input shaft transmits power from the converter to the overdrive gear set. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T > Component Information > Description and Operation > Page 4454 Input Shaft: Service and Repair INPUT SHELL - WITH A4OD REMOVAL 1. Remove snap ring from reverse sun gear and discard. 2. Remove thrust washer No. 7D066 from input shell. 3. Remove sun gear from input shell. INSTALLATION 1. Reverse procedure to install, noting the following: a. Lubrication hole in sun gear must be between stand-off pads on shell. b. Use a new snap ring for reverse sun gear. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Malfunction Indicator Lamp - A/T > Component Information > Description and Operation Malfunction Indicator Lamp - A/T: Description and Operation Transmission Control Indicator (TCIL) DESCRIPTION Indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Malfunction Indicator Lamp A/T > Component Information > Description and Operation Malfunction Indicator Lamp - A/T: Description and Operation Transmission Control Indicator (TCIL) DESCRIPTION Indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Output Shaft Hub and Ring Gear Output Shaft: Service and Repair Output Shaft Hub and Ring Gear WITH C6 DISASSEMBLE Output Shaft Hub And Ring Gear 1. Referring to the Output Shaft Hub And Ring Gear image, remove hub snap ring from ring gear, and lift hub from gear. ASSEMBLE 1. To assemble, position hub in ring gear. 2. Secure hub with snap ring, being sure the snap ring is fully engaged in groove. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Service and Repair > Output Shaft Hub and Ring Gear > Page 4466 Output Shaft: Service and Repair With C6 REMOVAL CAUTION: All parts must be handled carefully to avoid nicking or burring the bearing or mating surfaces. Lubricate all internal parts with clean automatic transmission fluid before assembling them. Do not use any other lubricants except on gaskets and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and seals when assembling transmission. Output Shaft Assembly 1. Remove governor. Refer to the Output Shaft Assembly image. 2. Remove snap ring that secures governor distributor on output shaft and slide it off front of shaft. 3. Remove seal ring from distributor. INSTALLATION 1. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Technical Service Bulletins > A/T - E40D Revised Rear Case Bushing Output Shaft Bearing/Bushing: Technical Service Bulletins A/T - E40D Revised Rear Case Bushing Article No. 95-11-12 06/05/95 TRANSMISSION - E4OD - REVISED REAR CASE BUSHING LIGHT TRUCK: 1989-95 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES ISSUE: A revised design transmission rear case bushing has been released for servicing the E40D transmission. The revised bushing incorporates one (1) lubrication groove on the bushing I.D. to supply additional lubrication to the No. 13 park gear thrust washer. ACTION: Always replace both front and rear case bushings when servicing the transmission if either case bushing is damaged and/or the No. 13 park gear thrust washer is heat stained or worn. Follow the case bushing replacement procedure as outlined in Section 07-01A of the appropriate Service Manual. Parts Block Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Description and Operation Parking Pawl: Description and Operation DESCRIPTION AND OPERATION The parking gear allows the output shaft to be mechanically locked to the case by the parking pawl. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Parking Mechanism Parking Pawl: Service and Repair Parking Mechanism WITH E4OD REMOVAL 1. Remove extension housing. 2. Remove two attaching bolts from park rod guide plate. 3. Remove parking pawl, return spring, and pin from case. Parking Pawl Abutment Removal 4. Remove Torx head bolt and parking pawl abutment. INSTALLATION 1. Reverse procedure to install, noting the following: a. Ensure return spring end rests on inside surface of case. b. Torque Torx head bolt to 16-20 ft lbs. c. Ensure plate dimple is facing inward. d. Torque park rod guide plate attaching bolts to 16-20 ft lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Parking Mechanism > Page 4476 Parking Pawl: Service and Repair Parking Pawl Linkage WITH C6 REMOVAL CAUTION: All parts must be handled carefully to avoid nicking or burring the bearing or mating surfaces. Lubricate all internal parts with clean automatic transmission fluid before assembling them. Do not use any other lubricants except on gaskets and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and seals when assembling transmission. Parking Pawl Mechanism 1. Unfasten and remove parking pawl guide plate from case. 2. Remove spring, parking pawl, and shaft from case. 3. Working from the pan mounting surface, drill a 1/8 inch hole through center of cupped plug. Pull plug from case with a wire hook. 4. Lift end of spring off park plate pin to relieve tension. Parking Plate Shaft Replacement Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Parking Mechanism > Page 4477 5. Thread a 1/4-20 X 1-1/4 inch bolt into park plate shaft. Pull shaft from case with screw. INSTALLATION 1. Reverse procedure to install. NOTE: When installing guide plate on case, make sure that actuating rod is seated in slot of plate. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation Planetary Gears: Description and Operation DESCRIPTION AND OPERATION The overdrive planetary system pinions mesh into the overdrive ring gear and overdrive sun gear and is splined to the input shaft. The forward planetary system pinions mesh into the forward ring gear and the forward-reverse sun gear and is splined to the output shaft. The reverse planetary system pinions mesh into the forward-reverse sun gear and the reverse ring gear and is splined to the low-reverse hub. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly and Assembly Planetary Gears: Service and Repair Disassembly and Assembly WITH C6 DISASSEMBLE CAUTION: All parts must be handled carefully to avoid nicking or burring the bearing or mating surfaces. Lubricate all internal parts with clean automatic transmission fluid before assembling them. Do not use any other lubricants except on gaskets and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and seals when assembling transmission. Sun Gear Snap Ring Replacement 1. Remove rear snap ring from sun gear. Input Shell And Sun Gear Assembly 2. Remove thrust washer. 3. Working from inside shell, remove sun gear. Remove forward snap ring. ASSEMBLE 1. Reverse procedure to assemble. NOTE: When installing sun gear, ensure longer end is at the rear. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 4483 Planetary Gears: Service and Repair Reverse Planetary Carrier WITH E4OD REMOVAL 1. Remove rear and front thrust washers from carrier. INSTALLATION 1. Reverse procedure to install, using grease to hold thrust washers in place. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Description and Operation Electronic Pressure Control Solenoid: Description and Operation DESCRIPTION The Electronic Pressure Control (EPC) Solenoid is a Variable Force Solenoid. The VFS-type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. OPERATION The EPC solenoid supplies Electronic Pressure Control which regulates transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and the line modulator circuits. These two pressures control the clutch application pressures. CAUTION: The electronic pressure control pressure output from the variable force solenoid is NOT adjustable. Any modification to the electronic pressure control solenoid will affect the transmission warranty. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation Power Control Module (PCM). Description The operation of the E4OD automatic transmission is controlled by the PCM. Many input sensors provide information to the PCM, which then controls the actuators which affect transmission operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T - AODE/4R70W Reusable Pan Gasket/Filter Seals and Gaskets: Technical Service Bulletins A/T - AODE/4R70W Reusable Pan Gasket/Filter Article No. 95-8-4 04/24/95 ^ LEAKS - AODE/4R70W - REUSABLE PAN GASKET AND FILTER ^ TRANSMISSION - AODE/4R70W - REUSABLE PAN GASKET AND FILTER - SERVICE TIP FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to advise of updated information. ISSUE: The AODE/4R70W transmission pan gaskets and filter may be reusable. ACTION: Refer to the following to determine if the transmission pan gasket and/or filter should be reused. The AODE/4R7OW transmission pan gasket has been designed to be reusable if it is removed for a non-leak related transmission service. The gasket should be inspected for damage and cleaned, along with the mating surfaces, before reuse. If the gasket requires replacement, retain the original gasket per the parts retention and return procedures as outlined in the Warranty and Policy Manual. NOTE: THE PAN GASKET IS NOT INCLUDED IN THE GASKET AND SEAL KIT. IT CAN ONLY BE ORDERED SEPARATELY. The transmission fluid filter has also been designed to be reuseable if removed from a transmission which did not have any component failure. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-19-12 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000, 510000, 590000, 597997 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation Brake Switch - TCC: Description and Operation Brake On/Off (BOO) Switch DESCRIPTION The Brake On/0ff switch tells the powertrain control module when the brakes are applied. The switch is closed when the brakes are applied and open when they are released. FUNCTION Disengages torque converter clutch when brake is applied. RELATED SYMPTOMS Failed on or not connected - Torque converter clutch will not engage at less than 1/3 throttle. Failed off - Torque converter clutch will not disengage when brake is applied. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Description and Operation > Accelerator Pedal (AP) Sensor Throttle Position Sensor/Switch: Description and Operation Accelerator Pedal (AP) Sensor Accelerator Pedal (AP) Sensor DESCRIPTION The Accelerator Pedal (AP) Sensor is mounted on the accelerator pedal and detects the position of the accelerator pedal. OPERATION The accelerator pedal position information is sent as a voltage signal to the PCM. The PCM uses this information to determine shift scheduling and electronic pressure control. FUNCTION If a malfunction occurs in the AP sensor circuit, the PCM will recognize that the AP signal is out of specification. The PCM will then operate the E4OD at a high line pressure to prevent transmission damage. This higher line pressure results in harsh upshifts and engagements. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Description and Operation > Accelerator Pedal (AP) Sensor > Page 4503 Throttle Position Sensor/Switch: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor Description The Throttle Position (TP) sensor is a potentiometer attached to the fuel injection pump and is operated by the throttle lever. Operation The TP sensor is incorporated to provide an electrical signal, which is proportional to the amount of fuel being delivered, as an input to the Powertrain Control Module (PCM). Based on this information, the TP sensor provides the proper shift scheduling and torque capacity. Should a malfunction occur in the TP sensor circuit, the electrical signal sent to the PCM will be recognized as erroneous. When this out-of-specification signal is detected, the PCM will operate the E4OD at a higher line pressure to protect the transmission from potential damage. This high line pressure, results in harsh upshifts and engagements. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power/Economy Mode Switch, A/T Transmission Mode Switch: Description and Operation Power/Economy Mode Switch, A/T Transmission Control Switch (TCS) DESCRIPTION The Transmission Control Switch (TCS) is a momentary contact switch which disables 4th gear operation and enables engine braking when activated. OPERATION When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM). The PCM then energizes the Transmission Control Indicator Lamp (TCIL) and the Coast Clutch Solenoid (CCS), applying the coast clutch to provide engine braking and cancels fourth gear operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power/Economy Mode Switch, A/T > Page 4508 Transmission Mode Switch: Description and Operation Transmission Mode Switch Transmission Control Switch (TCS) DESCRIPTION The Transmission Control Switch (TCS) is a momentary contact switch which disables 4th gear operation and enables engine braking when activated. OPERATION When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM). The PCM then energizes the Transmission Control Indicator Lamp (TCIL) and the Coast Clutch Solenoid (CCS), applying the coast clutch to provide engine braking and cancels fourth gear operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: Customer Interest A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission Transmission Position Switch/Sensor: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission > Page 4524 Transmission Position Switch/Sensor: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only > Page 4527 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission Transmission Position Switch/Sensor: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission > Page 4530 Transmission Position Switch/Sensor: Testing and Inspection With 4R70W Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Output Shaft Speed Sensor <--> [Transmission Speed Sensor, A/T] > Component Information > Locations Output Shaft Speed Sensor: Locations The Output Shaft Speed Sensor is located at the LH rear of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor PURPOSE Used as an input to determine shift schedule and Electronic Pressure Control (EPC) for temperature effects. DESCRIPTION The Transmission Fluid Temperature (TFT) sensor is a temperature-sensitive device called a thermistor it is located in the solenoid body assembly it sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with the transmission fluid temperature. OPERATION The PCM uses the voltage signal to determine whether a cold start shift schedule is necessary. The cold start shift schedule lowers shift speeds to allow for the reduced performance of cold engine operation. The TFT is part of the transmission solenoid assembly and is not replaced separately. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Lock <--> [Shift Interlock, A/T] > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove steering column. 2. Unclip wire terminal from shift interlock actuator. 3. Remove two screws from insert plate and shift interlock actuator. INSTALLATION 1. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Manual Shift Lever Grommet Shifter A/T: Service and Repair Manual Shift Lever Grommet With E4OD REMOVAL Shift Linkage Grommet Replacement NOTE: Some lever assemblies incorporate an oil impregnated plastic grommet in the end of the lever arm. 1. Place the lower jaw of the tool between the manual lever and control rod. Position the stop pin against the end of the control rod and force the rod out of the grommet. 2. Remove grommet from manual lever by cuffing off large shoulder with knife. NOTE: The grommet must be removed from the manual lever and a new one installed each time the rod is disconnected. INSTALLATION 1. Prior to installing a new grommet, adjust the stop pin to 1/2 inch and coat the outside of the grommet with lubricant. Then place the grommet on the stop pin and force it into the manual lever hole. Turn the grommet several times to be sure it is properly seated. 2. Adjust stop pin to the height shown in the Shift Linkage Grommet Replacement image. The pin height is determined by the length of the rod end which is to be installed into the grommet. If the pin height is not adjusted, the control rod may be pushed too far through the grommet, causing damage to the grommet retaining lip. 3. With the pin height properly adjusted, position the control rod on the tool and force the rod into the grommet until the groove in the rod seats on the inner retaining lip of the grommet. Be sure the rod protrudes through the grommet approximately 1/4 inch after installation. With C6 REMOVAL Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Manual Shift Lever Grommet > Page 4545 Fig. 6 Replacement Of Shift Linkage Grommet NOTE: Some lever assemblies incorporate an oil impregnated plastic grommet in the end of the lever arm. The special tool shown, in the Shift Linkage Grommet Replacement image, is required to install the grommet in the manual lever, and to install the manual linkage rod into the grommet. Remove and install the grommet as follows: 1. Place the lower jaw of the tool between the manual lever and control rod. 2. Position the stop pin against the end of the control rod and force the rod out of the grommet. 3. Remove grommet from manual lever by cutting off the large shoulder with knife. NOTE: The grommet must be removed from the manual lever and a new one installed each time the rod is disconnected. INSTALLATION 1. Before installing a new grommet, adjust the stop pin to 1/2 inch and coat the outside of the grommet with lubricant. Then place the grommet on the stop pin and force it into the manual lever hole. Turn the grommet several times to be sure it is properly seated. 2. Readjust the stop pin to the height shown in the Shift Linkage Grommet Replacement image. The pin height is determined by the length of the rod end which is to be installed into the grommet. CAUTION: If the pin height is not adjusted, the control rod may be pushed too far through the grommet, causing damage to the grommet retaining lip. 3. With the pin height properly adjusted, position the control rod on the tool and force the rod into the grommet until the groove in the rod seats on the inner retaining lip of the grommet. NOTE: Be sure the rod protrudes through the grommet approximately 1/4 inch after installation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Manual Shift Lever Grommet > Page 4546 Shifter A/T: Service and Repair Manual Shift Lever Seal REMOVAL 1. Remove manual lever position sensor connector. Check condition of electrical connectors and terminals, then repair as needed. 2. Remove lever control rod from manual lever, then the two manual lever position sensor bolts. 3. Remove shift cable or linkage from lever. Remove cable and fitting from ball stud using a screwdriver. 4. Loosen oil pan attaching bolts and drain fluid from transmission, then remove attaching bolts and pan. 5. Remove filter and seal assembly. Ensure seal is removed from bore. Manual Lever Roll Pin Removal 6. Remove manual lever roll pin using remover tool No. T78P-3504-N or equivalent. 7. Remove inner detent lever nut. Hold lever with crescent wrench to prevent strain on lever assembly. Manual Lever Seal Removal 8. Remove inner detent lever and park actuating rod assembly from manual lever. 9. Remove manual lever. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Manual Shift Lever Grommet > Page 4547 Manual Lever Seal Removal 10. Remove manual lever seal using seal remover tool No T74P-77248-A and slide hammer tool No. T5OT-1OO-A or equivalent. INSTALLATION 1. Reverse procedure to install, noting the following: a. Install seal using shift lever seal replacer tool No. T74P-77498-A or equivalent. b. Install new outer manual lever nut and torque to 20-29 ft lbs. c. Inner detent lever must be sealed on flats of shaft, and rod assembly must be through guide plate. d. Inner lever pin must be aligned with manual lever. e. Align manual lever position sensor for Neutral gear position using gear position sensor adjuster No. T89T-70010-J or equivalent. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 97-23-15 > Nov > 97 > A/T - C6/E4OD Difficulty Shifting From Park Shift Cable: Customer Interest A/T - C6/E4OD Difficulty Shifting From Park Article No. 97-23-15 TRANSMISSION-C6 AND E4OD-DIFFICULTY SHIFTING FROM PARK-SEVERE ENVIRONMENTAL CONDITIONS-COMMERCIAL STRIPPED CHASSIS LIGHT TRUCK: 1992-96 ECONOLINE This TSB article is being republished in its entirety to correct the part applications. ISSUE: Difficulty shifting from Park when the vehicle is exposed to extreme environmental conditions (e.g., off-road in cold weather or mining pits) may occur on some vehicles. This is due to off-road mud and/or mining sludge accumulating and freezing around the exposed end of the shift cable at the transmission lever. ACTION: Replace the factory-installed shift cable with a revised cable that has a protective rubber boot around the exposed end. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the factory-installed shift cable by referring to the 1995 Econoline Service Manual, Page 07-05-7. 2. Remove two (2) bolts from the transmission-mounted bracket and discard bracket. 3. For C6 applications, remove the kickdown cable connections. NOTE: READJUSTMENT WILL BE REQUIRED AFTER NEW BOOTED CABLE IS INSTALLED. 4. Install new booted Shift Cable (-7E395-) and transmission mount bracket. Refer to the Service Manual, Page 07-05-8. 5. Adjust cable per the Service Manual, Page 07-05-11. 6. Reconnect kickdown cable for C6 applications. Refer to the Resetting Self-Adjuster And Adjusting Kickdown Cable procedure found in this TSB article. RESETTING SELF-ADJUSTER AND ADJUSTING KICKDOWN CABLE The C6 kickdown cable is initially a self-adjusting linkage. Any alteration that may change the dimensional relationship between the transmission-mounted cable bracket and the throttle body-mounted cable bracket will require a resetting of the cable self-adjuster and repeat of the self-adjustment procedure. The self-adjuster is located at the throttle body end of the kickdown cable assembly. A steel locking clip is located on top of the cable assembly (7.5L) or on the side of the cable assembly (4.9L and 5.8L) just before it passes through the throttle body bracket. The locking clip retains an adjustable splined housing that protrudes through the throttle body bracket and encloses the steel downshift cable. 1. Reset the self-adjuster to a non-adjusted position. Slightly depress the steel locking clip and then push the adjustable housing toward the throttle body bracket until it seats (Figure 1). Release the locking clip. 2. Adjusting the kickdown. Install a 5mm (0.200") spacer between the cable tip and the plastic cable end fitting located at the throttle lever (Figure 2). Ratchet the cable adjusting mechanism to the correct setting by rotating throttle to a wide open position by hand or using the driver's throttle pedal. Remove the Smm (0.200") spacer. PART NUMBER PART NAME F6UZ-7E395-AA Shift Cable (E4OD Transmission) F6UZ-7E395-BA Shift Cable (C6 Transmission) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-11-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION 972315A Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 97-23-15 > Nov > 97 > A/T - C6/E4OD Difficulty Shifting From Park > Page 4557 DESCRIPTION Replace Shift Control Cable TIME 0.7 Hr. DEALER CODING BASIC PART NO. 7E395 CONDITION CODE 41 OASIS CODES: 503300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97-23-15 > Nov > 97 > A/T - C6/E4OD Difficulty Shifting From Park Shift Cable: All Technical Service Bulletins A/T - C6/E4OD Difficulty Shifting From Park Article No. 97-23-15 TRANSMISSION-C6 AND E4OD-DIFFICULTY SHIFTING FROM PARK-SEVERE ENVIRONMENTAL CONDITIONS-COMMERCIAL STRIPPED CHASSIS LIGHT TRUCK: 1992-96 ECONOLINE This TSB article is being republished in its entirety to correct the part applications. ISSUE: Difficulty shifting from Park when the vehicle is exposed to extreme environmental conditions (e.g., off-road in cold weather or mining pits) may occur on some vehicles. This is due to off-road mud and/or mining sludge accumulating and freezing around the exposed end of the shift cable at the transmission lever. ACTION: Replace the factory-installed shift cable with a revised cable that has a protective rubber boot around the exposed end. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the factory-installed shift cable by referring to the 1995 Econoline Service Manual, Page 07-05-7. 2. Remove two (2) bolts from the transmission-mounted bracket and discard bracket. 3. For C6 applications, remove the kickdown cable connections. NOTE: READJUSTMENT WILL BE REQUIRED AFTER NEW BOOTED CABLE IS INSTALLED. 4. Install new booted Shift Cable (-7E395-) and transmission mount bracket. Refer to the Service Manual, Page 07-05-8. 5. Adjust cable per the Service Manual, Page 07-05-11. 6. Reconnect kickdown cable for C6 applications. Refer to the Resetting Self-Adjuster And Adjusting Kickdown Cable procedure found in this TSB article. RESETTING SELF-ADJUSTER AND ADJUSTING KICKDOWN CABLE The C6 kickdown cable is initially a self-adjusting linkage. Any alteration that may change the dimensional relationship between the transmission-mounted cable bracket and the throttle body-mounted cable bracket will require a resetting of the cable self-adjuster and repeat of the self-adjustment procedure. The self-adjuster is located at the throttle body end of the kickdown cable assembly. A steel locking clip is located on top of the cable assembly (7.5L) or on the side of the cable assembly (4.9L and 5.8L) just before it passes through the throttle body bracket. The locking clip retains an adjustable splined housing that protrudes through the throttle body bracket and encloses the steel downshift cable. 1. Reset the self-adjuster to a non-adjusted position. Slightly depress the steel locking clip and then push the adjustable housing toward the throttle body bracket until it seats (Figure 1). Release the locking clip. 2. Adjusting the kickdown. Install a 5mm (0.200") spacer between the cable tip and the plastic cable end fitting located at the throttle lever (Figure 2). Ratchet the cable adjusting mechanism to the correct setting by rotating throttle to a wide open position by hand or using the driver's throttle pedal. Remove the Smm (0.200") spacer. PART NUMBER PART NAME F6UZ-7E395-AA Shift Cable (E4OD Transmission) F6UZ-7E395-BA Shift Cable (C6 Transmission) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-11-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION 972315A Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 97-23-15 > Nov > 97 > A/T - C6/E4OD Difficulty Shifting From Park > Page 4563 DESCRIPTION Replace Shift Control Cable TIME 0.7 Hr. DEALER CODING BASIC PART NO. 7E395 CONDITION CODE 41 OASIS CODES: 503300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 4564 Shift Cable: Adjustments ADJUST 1. Place selector lever in Overdrive position, then hang a 3 lb weight from lever. Shift Cable Replacement 2. Raise and support vehicle on a hoist, then remove shift cable from transmission lever ball stud. 3. Pull down lock tab on shift cable body, then position transmission shift lever in Overdrive position by moving lever to front-most position and clicking back two detents. 4. Connect cable end fitting to transmission lever ball stud, then push up on lock tab to lock cable in correctly adjusted position. 5. Lower vehicle and remove weight from selector lever, then check park engagement and ensure transmission operation corresponds to all detent positions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Modulator > Component Information > Description and Operation Shift Modulator: Description and Operation Fig. 7 Altitude Compensating Vacuum Diaphragm ALTITUDE-COMPENSATED VACUUM DIAPHRAGM The unit incorporates an evacuated bellows that is sensitive to barometric pressure. Barometric pressure decreases about one inch Hg for each 1000 feet altitude increase. The bellows decreases throttle pressure at higher altitude to make the shift feel comparable to lower altitude. The engine power loss at high altitude is offset by a lower throttle pressure and the shifts remain smooth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip Sun Gear: Technical Service Bulletins A/T - 4R70W Needle Bearing/Race Kit Service Tip Article No. 03-26-1 01/12/04 TRANSMISSION - 4R70W - NEW SERVICE PART - NUMBER 5 NEEDLE BEARING AND RACE KIT - SERVICE TIP FORD: 1994-1997 THUNDERBIRD, 1994-2003 CROWN VICTORIA, MUSTANG, E SERIES 1996-2001 EXPLORER 1994-2003 F SERIES LINCOLN: 1994-1998 MARK VIII 1994-2003 TOWN CAR MERCURY: 1994-1997 COUGAR 1994-2003 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE Should repairs become necessary on a 4R70W transmission involving replacement of the forward or reverse clutch sungear, and/or the number five (# 5) thrust bearing, these service pants all must be replaced in combination. A mismatch of service parts may cause an internal noise or a loss of forward and/or reverse. A new service kit has been produced to eliminate the mismatch of service pants. This new kit services all 4R70W transmissions built prior to the 2004 model. ACTION A new Service Kit 4L3Z-7D234-M has been produced to eliminate the mismatch of service parts. The kit contains the following: ^ A new two (2) piece number five (# 5) thrust bearing assembly (70234 bearing and 70235 race) (Figure 1) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 4572 ^ A forward clutch sun gear (7A399) (Figure 2) ^ A reverse sun gear (7A019) (Figure 3) SERVICE TIP To install, refer to the latest version Workshop Manual for disassembly and reassembly of the transmission. CAUTION ALL COMPONENTS IN THE KIT MUST BE INSTALLED OR THE REPAIR MAY NOT BE EFFECTIVE AND MAY CAUSE AN INTERNAL NOISE OR LOSS OF FORWARD AND~OR REVERSE. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 4573 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Description and Operation > Accelerator Pedal (AP) Sensor Throttle Position Sensor/Switch: Description and Operation Accelerator Pedal (AP) Sensor Accelerator Pedal (AP) Sensor DESCRIPTION The Accelerator Pedal (AP) Sensor is mounted on the accelerator pedal and detects the position of the accelerator pedal. OPERATION The accelerator pedal position information is sent as a voltage signal to the PCM. The PCM uses this information to determine shift scheduling and electronic pressure control. FUNCTION If a malfunction occurs in the AP sensor circuit, the PCM will recognize that the AP signal is out of specification. The PCM will then operate the E4OD at a high line pressure to prevent transmission damage. This higher line pressure results in harsh upshifts and engagements. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position Sensor/Switch, A/T > Component Information > Description and Operation > Accelerator Pedal (AP) Sensor > Page 4578 Throttle Position Sensor/Switch: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor Description The Throttle Position (TP) sensor is a potentiometer attached to the fuel injection pump and is operated by the throttle lever. Operation The TP sensor is incorporated to provide an electrical signal, which is proportional to the amount of fuel being delivered, as an input to the Powertrain Control Module (PCM). Based on this information, the TP sensor provides the proper shift scheduling and torque capacity. Should a malfunction occur in the TP sensor circuit, the electrical signal sent to the PCM will be recognized as erroneous. When this out-of-specification signal is detected, the PCM will operate the E4OD at a higher line pressure to protect the transmission from potential damage. This high line pressure, results in harsh upshifts and engagements. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve, A/T > Component Information > Description and Operation Throttle Valve: Description and Operation DESCRIPTION AND OPERATION The primary throttle valve generates throttle pressure in the same way as earlier models and at the same rate with respect to manifold vacuum. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments Throttle Valve Cable/Linkage: Adjustments NOTE: Some engines use an Air Bypass (ISC) that does not affect throttle position. Therefore, automatic idle setting does not affect TV cable adjustment. 1. Set parking brake, then place shift selector in NEUTRAL position. Do not check or set Throttle Valve (TV) pressure in PARK. 2. Remove air cleaner cover and inlet tube from throttle body inlet to access throttle lever and cable assembly. 3. Using a wide blade screwdriver, pry cable assembly out of grommet on throttle body lever. 4. Ensure plastic block slides freely on notched rod. 5. While holding throttle lever firmly against its idle stop, push grooved pin into grommet on throttle lever as far as it will go. NOTE: While pushing pin into grommet, ensure throttle lever does not move away from idle stop. 6. Ensure grooved pin is fully installed while holding throttle lever firmly against idle stop. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip Thrust Washer/Bearing: Technical Service Bulletins A/T - 4R70W Needle Bearing/Race Kit Service Tip Article No. 03-26-1 01/12/04 TRANSMISSION - 4R70W - NEW SERVICE PART - NUMBER 5 NEEDLE BEARING AND RACE KIT - SERVICE TIP FORD: 1994-1997 THUNDERBIRD, 1994-2003 CROWN VICTORIA, MUSTANG, E SERIES 1996-2001 EXPLORER 1994-2003 F SERIES LINCOLN: 1994-1998 MARK VIII 1994-2003 TOWN CAR MERCURY: 1994-1997 COUGAR 1994-2003 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE Should repairs become necessary on a 4R70W transmission involving replacement of the forward or reverse clutch sungear, and/or the number five (# 5) thrust bearing, these service pants all must be replaced in combination. A mismatch of service parts may cause an internal noise or a loss of forward and/or reverse. A new service kit has been produced to eliminate the mismatch of service pants. This new kit services all 4R70W transmissions built prior to the 2004 model. ACTION A new Service Kit 4L3Z-7D234-M has been produced to eliminate the mismatch of service parts. The kit contains the following: ^ A new two (2) piece number five (# 5) thrust bearing assembly (70234 bearing and 70235 race) (Figure 1) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 4590 ^ A forward clutch sun gear (7A399) (Figure 2) ^ A reverse sun gear (7A019) (Figure 3) SERVICE TIP To install, refer to the latest version Workshop Manual for disassembly and reassembly of the transmission. CAUTION ALL COMPONENTS IN THE KIT MUST BE INSTALLED OR THE REPAIR MAY NOT BE EFFECTIVE AND MAY CAUSE AN INTERNAL NOISE OR LOSS OF FORWARD AND~OR REVERSE. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 4591 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 03-21-18 > Oct > 03 > A/T - Driveline Vibration W/Converter Engaged Torque Converter: Customer Interest A/T - Driveline Vibration W/Converter Engaged Article No. 03-21-18 10/06/03 ^ VIBRATION - DRIVELINE RESONANCE/VIBRATION BETWEEN 1400 AND 2000 RPM WITH CONVERTER CLUTCH ENGAGED DURING MEDIUM TO HEAVY THROTTLE CONDITIONS VEHICLES WITH 7.3L DI TURBO ENGINE AND TRANSMISSION BUILT PRIOR TO 11/13/95 (5L13) ^ TRANSMISSION - E40D - DRIVELINE RESONANCE/VIBRATION BETWEEN 1400 AND 2000 RPM WITH CONVERTER CLUTCH ENGAGED DURING MEDIUM TO HEAVY THROTTLE CONDITIONS - VEHICLES WITH 7.3L DI TURBO ENGINE AND TRANSMISSION BUILT PRIOR TO 11/13/95 (5L13) FORD: 1995-1996 E-350, F-250 CREW CAB, F-350 CREW CAB Article 96-26-21 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE Some vehicles with transmissions built prior to 11/13/95 (5L13) may exhibit a driveline resonance/vibration between 1400 and 2000 RPM with the torque converter clutch engaged. This may be caused by the torque converter. ACTION Prior to torque converter replacement, refer to the following Service Procedure for details to verify conditions. SERVICE PROCEDURE 1. Verify the resonance/vibration does not occur in neutral and is most noticeable between 1400 and 2000 RPM with the converter clutch engaged during medium to heavy throttle conditions. Also watch for the vibration to diminish at engine speeds lower than 1400 and higher than 2000 RPM. If the concern meets all of these conditions and the transmission has a built date prior to 11/13/95 (5L13), replace the torque converter. Refer to the appropriate Service Manual for removal and installation procedures. 2. If the vibration concerns do not meet the conditions, check for non-factory installed items that could affect driveline and verify proper installation. Also refer to the appropriate Service Manual, Section 05-00 for diagnosis and testing. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-26-21 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: Customer Interest A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 4604 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 03-21-18 > Oct > 03 > A/T - Driveline Vibration W/Converter Engaged Torque Converter: All Technical Service Bulletins A/T - Driveline Vibration W/Converter Engaged Article No. 03-21-18 10/06/03 ^ VIBRATION - DRIVELINE RESONANCE/VIBRATION BETWEEN 1400 AND 2000 RPM WITH CONVERTER CLUTCH ENGAGED DURING MEDIUM TO HEAVY THROTTLE CONDITIONS VEHICLES WITH 7.3L DI TURBO ENGINE AND TRANSMISSION BUILT PRIOR TO 11/13/95 (5L13) ^ TRANSMISSION - E40D - DRIVELINE RESONANCE/VIBRATION BETWEEN 1400 AND 2000 RPM WITH CONVERTER CLUTCH ENGAGED DURING MEDIUM TO HEAVY THROTTLE CONDITIONS - VEHICLES WITH 7.3L DI TURBO ENGINE AND TRANSMISSION BUILT PRIOR TO 11/13/95 (5L13) FORD: 1995-1996 E-350, F-250 CREW CAB, F-350 CREW CAB Article 96-26-21 is being republished in its entirety as part of a consolidated 7.3L diagnostic aid booklet. ISSUE Some vehicles with transmissions built prior to 11/13/95 (5L13) may exhibit a driveline resonance/vibration between 1400 and 2000 RPM with the torque converter clutch engaged. This may be caused by the torque converter. ACTION Prior to torque converter replacement, refer to the following Service Procedure for details to verify conditions. SERVICE PROCEDURE 1. Verify the resonance/vibration does not occur in neutral and is most noticeable between 1400 and 2000 RPM with the converter clutch engaged during medium to heavy throttle conditions. Also watch for the vibration to diminish at engine speeds lower than 1400 and higher than 2000 RPM. If the concern meets all of these conditions and the transmission has a built date prior to 11/13/95 (5L13), replace the torque converter. Refer to the appropriate Service Manual for removal and installation procedures. 2. If the vibration concerns do not meet the conditions, check for non-factory installed items that could affect driveline and verify proper installation. Also refer to the appropriate Service Manual, Section 05-00 for diagnosis and testing. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-26-21 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: All Technical Service Bulletins A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 4614 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 4619 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 4620 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure Torque Converter: All Technical Service Bulletins A/T Torque Converter - Leak Test Procedure Article No. 96-24-9 11/18/96 TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1984-90 BRONCO II 1984-96 BRONCO 1984-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: A new torque converter leak test tool has been released. The current leak test tool has been discontinued by the manufacturer. The new tool will be available to all dealers in 1997. ACTION: When using the new leak test tool, a new procedure must be followed. Refer to the following Service Procedure and/or the 1997 Service/Workshop Manuals when using the new leak test tool. NEW TOOL NUMBER Description Tool Number Torque converter Leak Test Tool and Gasket 014-R1075 SERVICE PROCEDURE 1. Clean the outside surface of the torque converter. CAUTION: BE CAREFUL NOT TO DAMAGE THE CONVERTER HUB FINISH WHEN INSTALLING THE TOOL. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 4625 2. Install the Torque Converter Leak Test Tool and Gasket (O14-R1075) into the converter hub. Figure 1. WARNING: ALWAYS USE PROPER SAFETY PROCEDURES WHILE USING PRESS. CAUTION: DO NOT DAMAGE THE CONVERTER BY APPLYING EXCESSIVE FORCE FROM THE PRESS. USE ONLY ENOUGH FORCE TO SEAL TOOL INTO THE CONVERTER. 3. Place the torque converter with the tool installed into press and apply enough force to seal tool into the converter. Figure 2. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 4626 4. Using clean, dry shop air only, apply air pressure of 552 kPa (80 psi) maximum to the valve on the tool. Refer to Figure 3. 5. With air pressure applied to the valve, inspect for any air leaks at the studs, seams and pilot hub. A soap bubble solution may be applied around those areas to aid in diagnosis. If any leaks are present, replace the converter. 6. Disconnect the air line and release the air pressure from the tool by pulling on the release ring and then slowly releasing the press. Refer to Figure 4. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 4627 7. Turn the torque converter and tool upside down and reinstall into the press. Repeat Steps 2-6 to check for leaks on the opposite side. Refer to Figure 5. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 504000, 510000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 942115 > Oct > 94 > A/T - E4OD Torque Converter Scraping/Dragging Noise Torque Converter: All Technical Service Bulletins A/T - E4OD Torque Converter Scraping/Dragging Noise Article No. 94-21-15 10/19/94 TRANSMISSION - E40D - TORQUE CONVERTER MAKING DRAGGING OR SCRAPING NOISE DURING ASSEMBLY - VEHICLES WITH 7.3L DIRECT INJECTION TURBO DIESEL - SERVICE TIPS LIGHT TRUCK: 1995 E-250, E-350, F-250, F-350 ISSUE: The direct injection turbo diesel uses a multi-plate torque converter. When installing the torque converter into some transmissions, a scraping or dragging noise may be heard while rotating the torque converter. This may be a normal condition with the multi-plate torque converters. ACTION: Refer to the following Steps for proper diagnosis. SERVICE PROCEDURE 1. Install the Torque Converter Handies T81P-7902-C (Figure 1). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 942115 > Oct > 94 > A/T - E4OD Torque Converter Scraping/Dragging Noise > Page 4632 2. Lift up slightly on the torque converter pilot and center the torque converter in the housing. Refer to Figure 2. 3. Holding the torque converter by the pilot, rotate the torque converter using the Torque Converter Handles (T81P-7902-C). If the noise is no longer present, the condition is normal and no further action is required. 4. If the noise is still present, follow the diagnosis procedures as outlined in the Service Manual, Section 07-O1A, and service as required. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 4638 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 4639 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure Torque Converter: All Technical Service Bulletins A/T Torque Converter - Leak Test Procedure Article No. 96-24-9 11/18/96 TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1984-90 BRONCO II 1984-96 BRONCO 1984-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: A new torque converter leak test tool has been released. The current leak test tool has been discontinued by the manufacturer. The new tool will be available to all dealers in 1997. ACTION: When using the new leak test tool, a new procedure must be followed. Refer to the following Service Procedure and/or the 1997 Service/Workshop Manuals when using the new leak test tool. NEW TOOL NUMBER Description Tool Number Torque converter Leak Test Tool and Gasket 014-R1075 SERVICE PROCEDURE 1. Clean the outside surface of the torque converter. CAUTION: BE CAREFUL NOT TO DAMAGE THE CONVERTER HUB FINISH WHEN INSTALLING THE TOOL. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 4644 2. Install the Torque Converter Leak Test Tool and Gasket (O14-R1075) into the converter hub. Figure 1. WARNING: ALWAYS USE PROPER SAFETY PROCEDURES WHILE USING PRESS. CAUTION: DO NOT DAMAGE THE CONVERTER BY APPLYING EXCESSIVE FORCE FROM THE PRESS. USE ONLY ENOUGH FORCE TO SEAL TOOL INTO THE CONVERTER. 3. Place the torque converter with the tool installed into press and apply enough force to seal tool into the converter. Figure 2. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 4645 4. Using clean, dry shop air only, apply air pressure of 552 kPa (80 psi) maximum to the valve on the tool. Refer to Figure 3. 5. With air pressure applied to the valve, inspect for any air leaks at the studs, seams and pilot hub. A soap bubble solution may be applied around those areas to aid in diagnosis. If any leaks are present, replace the converter. 6. Disconnect the air line and release the air pressure from the tool by pulling on the release ring and then slowly releasing the press. Refer to Figure 4. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 4646 7. Turn the torque converter and tool upside down and reinstall into the press. Repeat Steps 2-6 to check for leaks on the opposite side. Refer to Figure 5. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 504000, 510000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 942115 > Oct > 94 > A/T - E4OD Torque Converter Scraping/Dragging Noise Torque Converter: All Technical Service Bulletins A/T - E4OD Torque Converter Scraping/Dragging Noise Article No. 94-21-15 10/19/94 TRANSMISSION - E40D - TORQUE CONVERTER MAKING DRAGGING OR SCRAPING NOISE DURING ASSEMBLY - VEHICLES WITH 7.3L DIRECT INJECTION TURBO DIESEL - SERVICE TIPS LIGHT TRUCK: 1995 E-250, E-350, F-250, F-350 ISSUE: The direct injection turbo diesel uses a multi-plate torque converter. When installing the torque converter into some transmissions, a scraping or dragging noise may be heard while rotating the torque converter. This may be a normal condition with the multi-plate torque converters. ACTION: Refer to the following Steps for proper diagnosis. SERVICE PROCEDURE 1. Install the Torque Converter Handies T81P-7902-C (Figure 1). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 942115 > Oct > 94 > A/T - E4OD Torque Converter Scraping/Dragging Noise > Page 4651 2. Lift up slightly on the torque converter pilot and center the torque converter in the housing. Refer to Figure 2. 3. Holding the torque converter by the pilot, rotate the torque converter using the Torque Converter Handles (T81P-7902-C). If the noise is no longer present, the condition is normal and no further action is required. 4. If the noise is still present, follow the diagnosis procedures as outlined in the Service Manual, Section 07-O1A, and service as required. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 4652 Torque Converter: Description and Operation DESCRIPTION AND OPERATION The torque converter couples the engine to the input shaft of the transmission. It provides torque multiplication and absorbs engine shock caused by gear shifting. The converter clutch is an electrically controlled clutch which bypasses the torque converter. This eliminates torque converter slippage and excess heat generation, resulting in improved fuel economy and vehicle performance. The converter clutch is also used to minimize the perceived engine RPM change during upshifts and downshifts. The converter clutch hydraulic control allows only On/Off control of the clutch application. Converter clutch application and release is controlled by the Powertrain Control Module (PCM) or the transmission Electronic Control Assembly (ECA) through solenoid No. 3. The converter clutch (piston plate clutch and damper assembly) transmits engine power to the turbine hub and input shaft from the converter cover during lockup. The converter cover transmits power from the engine into the converter. The turbine is splined through the turbine hub to the input shaft and driven by fluid from the impeller. The impeller, driven by the converter cover, pumps transmission fluid within the torque converter. The reactor gives a hydraulic reaction yielding torque multiplication. Contained within the reactor is a one-way clutch that will hold the reactor stationary only when reaction is required. The impeller hub drives the pump drive gear. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Reactor One-Way Clutch Test Torque Converter: Testing and Inspection Torque Converter Reactor One-Way Clutch Test INSPECTION 1. Insert one-way clutch holding tool No. T77L-7902-R or equivalent in a stator thrust washer groove, then place converter clutch torquing tool No. T76L-7902-C or equivalent in converter pump drive hub to engage one-way clutch inner race. 2. Attach a torque wrench to torquing tool, Then turn wrench counterclockwise from direction of drive hub opening. One-way clutch should lock and hold a force of 10 ft lbs. 3. Turn wrench clockwise from direction of drive hub opening. One-way clutch should rotate freely until torquing tool contacts holding tool. 4. Repeat lock-up and hold tests for at least 5 different points in circle of clutch rotation. If, at any point, clutch fails to perform as indicated, replace torque converter, Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Reactor One-Way Clutch Test > Page 4655 Torque Converter: Testing and Inspection Converter Stator to Impeller Interference Check - With E4OD STATOR TO IMPELLER INTERFERENCE CHECK 1. Position stator support on bench, with spline end of shaft pointing up. 2. Mount converter on stator support with splines on one-way clutch inner race engaging mating splines of stator support. 3. Hold stator support stationary and try to rotate converter counterclockwise. The converter should rotate freely without any signs of interference or scraping within the converter assembly. 4. If there is any indication of scraping, the trailing edges of the stator blades may be interfering with the leading edges of the impeller blades. In such cases, replace the converter. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Torque Converter Reactor One-Way Clutch Test > Page 4656 Torque Converter: Testing and Inspection Torque Converter Turbine Interference Check - With E4OD STATOR TO TURBINE INTERFERENCE CHECK 1. Position converter on bench front side down. 2. Install stator support to engage mating splines of stator support shaft. 3. Install input shaft, engaging splines with turbine hub. 4. Hold stator shaft stationary and attempt to rotate the turbine with input shaft. The turbine should rotate freely in both directions without any signs of interference or scraping noise. 5. If interference exists, the stator front thrust washer may be worn, allowing stator to hit the turbine. In such cases, the converter must be replaced. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Check Valve: > 942114 > Oct > 94 > A/T - E4OD Vehicle Does Not Move Torque Converter Check Valve: Customer Interest A/T - E4OD Vehicle Does Not Move Article No. 94-21-14 10/19/94 TRANSMISSION - E40D - VEHICLE DOES NOT MOVE - DIAGNOSIS AND SERVICE TIPS LIGHT TRUCK: 1990-95 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES ISSUE: Some vehicles may experience some of the following symptoms: ^ No vehicle movement ^ Low one-way clutch overheating ^ Transmission fluid overheated and smells "burnt" These conditions may be caused by the check ball, located in the rear cooler line converter drainback check valve assembly, sticking. ACTION: Perform the following diagnosis and replace the converter drainback check valve if required. DIAGNOSTIC AND SERVICE PROCEDURES 1. Perform the diagnostics as outlined in the Service Manual, Section 07-01A. 2. Perform the "Transmission Oil Cooler Flow Test" found in "Diagnosis and Testing", Section 07-01A, of the Service Manual. Service as required. If no service is required, proceed to Step 3. 3. Remove the cooler line from the rear transmission cooler line fitting. Refer to Figure 1. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Check Valve: > 942114 > Oct > 94 > A/T - E4OD Vehicle Does Not Move > Page 4665 4. Using a small screwdriver, press on the check ball and make sure it moves freely inside the check valve. Refer to Figure 2. 5. Replace the converter drainback check valve if the ball does not move freely. 6. All internal transmission components and the torque converter must be checked for damage. Follow the Disassembly, Subassembly, Cleaning/inspection, and Reassembly procedures as outlined in the Service Manual, Section 07-01A, and service as required. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 503000, 510000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Check Valve: > 942114 > Oct > 94 > A/T - E4OD Vehicle Does Not Move Torque Converter Check Valve: All Technical Service Bulletins A/T - E4OD Vehicle Does Not Move Article No. 94-21-14 10/19/94 TRANSMISSION - E40D - VEHICLE DOES NOT MOVE - DIAGNOSIS AND SERVICE TIPS LIGHT TRUCK: 1990-95 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES ISSUE: Some vehicles may experience some of the following symptoms: ^ No vehicle movement ^ Low one-way clutch overheating ^ Transmission fluid overheated and smells "burnt" These conditions may be caused by the check ball, located in the rear cooler line converter drainback check valve assembly, sticking. ACTION: Perform the following diagnosis and replace the converter drainback check valve if required. DIAGNOSTIC AND SERVICE PROCEDURES 1. Perform the diagnostics as outlined in the Service Manual, Section 07-01A. 2. Perform the "Transmission Oil Cooler Flow Test" found in "Diagnosis and Testing", Section 07-01A, of the Service Manual. Service as required. If no service is required, proceed to Step 3. 3. Remove the cooler line from the rear transmission cooler line fitting. Refer to Figure 1. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Check Valve: > 942114 > Oct > 94 > A/T - E4OD Vehicle Does Not Move > Page 4671 4. Using a small screwdriver, press on the check ball and make sure it moves freely inside the check valve. Refer to Figure 2. 5. Replace the converter drainback check valve if the ball does not move freely. 6. All internal transmission components and the torque converter must be checked for damage. Follow the Disassembly, Subassembly, Cleaning/inspection, and Reassembly procedures as outlined in the Service Manual, Section 07-01A, and service as required. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 503000, 510000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration Torque Converter Clutch: Customer Interest A/T - Vibration/Shudder On Light Acceleration Article No. 95-23-4 11/20/95 FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to clarify Issue, Action, Service Procedure, and Operation. ISSUE: Torque converter clutch shudder or vibration may occur under light to moderate acceleration above 56 km/h (35 mph) while in 3rd or 4th gear or during 3-4 or 4-3 shifts. This condition may be noticeable on higher mileage vehicles (24,000 km/15,000 mi or more) when the torque converter clutch engages or disengages during light to moderate acceleration. ACTION: Perform normal diagnostics (i.e., linkage adjustment fluid level and condition, On-Board diagnostic check). If self test codes are present, service as required. If no DTCs are present, perform the following Service Procedure. SERVICE PROCEDURE 1. Drain all transmission fluid. Refer to the appropriate Service Manual, Section 07-01 for details. If fluid is burnt or heavily contaminated, repair as required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 4680 2. Remove transmission and replace the torque converter assembly with the correct torque converter. Refer to Figure 1. 3. Remove the transmission pan and clean transmission pan and pan magnet. 4. Inspect transmission pan gasket and filter. Reuse both pan gasket and filter if not damaged. 5. Reinstall filter, pan magnet, and transmission pan with original gasket. 6. Completely clean and flush transmission cooler and cooler lines. 7. Reinstall the transmission assembly. 8. Refill transmission with Mercon(R) Automatic Transmission Fluid (XT-2-QDX). Use only quart containers of Mercon(R) when refilling to ensure proper fluid quality is being used. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter Clutch: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 4681 PART NUMBER PART NAME XT-2-QDX Mercon(R) Automatic Transmission Fluid F5AZ-7902-ARM Torque Converter F5ZZ-7902-ARM Torque Converter F4LY-7902-ARM Torque Converter F4SZ-7902-BRM Torque Converter Please use the following repair description for each model described in the OPERATION/DESCRIPTION/TIME section of this TSB article: Perform electronic transmission diagnostics, replace torque converter, drain and fill transmission (including inspection of filter - replace if necessary), flush cooler and lines. Road test vehicle after repairs are complete. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-14-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952304A 1994-95 Econoline 4.6 Hrs. 952304B 1994-95 F-Series 4X2 4.4 Hrs. 952304C 1994-95 F-Series 4X4 6.0 Hrs. 952304D 1994-95 Mustang 3.8L 5.1 Hrs. 952304E 1994-95 Mustang 5.0L 5.3 Hrs. 952304F 1994-95 5.4 Hrs. Thunderbird/Cougar 4.6L 952304G 1994-95 5.3 Hrs. Thunderbird/Cougar 3.8L 952304H 1993-95 Mark VIII 5.4 Hrs. 952304I 1992-95 Crown 4.9 Hrs. Victoria/Grand Marquis/Town Car DEALER CODING CONDITION BASIC PART NO. CODE 7902 67 OASIS CODES: 501000, 502000, 504000, 510000, 597997, 703000, 703200, 703400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration Torque Converter Clutch: All Technical Service Bulletins A/T - Vibration/Shudder On Light Acceleration Article No. 95-23-4 11/20/95 FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to clarify Issue, Action, Service Procedure, and Operation. ISSUE: Torque converter clutch shudder or vibration may occur under light to moderate acceleration above 56 km/h (35 mph) while in 3rd or 4th gear or during 3-4 or 4-3 shifts. This condition may be noticeable on higher mileage vehicles (24,000 km/15,000 mi or more) when the torque converter clutch engages or disengages during light to moderate acceleration. ACTION: Perform normal diagnostics (i.e., linkage adjustment fluid level and condition, On-Board diagnostic check). If self test codes are present, service as required. If no DTCs are present, perform the following Service Procedure. SERVICE PROCEDURE 1. Drain all transmission fluid. Refer to the appropriate Service Manual, Section 07-01 for details. If fluid is burnt or heavily contaminated, repair as required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 4687 2. Remove transmission and replace the torque converter assembly with the correct torque converter. Refer to Figure 1. 3. Remove the transmission pan and clean transmission pan and pan magnet. 4. Inspect transmission pan gasket and filter. Reuse both pan gasket and filter if not damaged. 5. Reinstall filter, pan magnet, and transmission pan with original gasket. 6. Completely clean and flush transmission cooler and cooler lines. 7. Reinstall the transmission assembly. 8. Refill transmission with Mercon(R) Automatic Transmission Fluid (XT-2-QDX). Use only quart containers of Mercon(R) when refilling to ensure proper fluid quality is being used. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter Clutch: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 4688 PART NUMBER PART NAME XT-2-QDX Mercon(R) Automatic Transmission Fluid F5AZ-7902-ARM Torque Converter F5ZZ-7902-ARM Torque Converter F4LY-7902-ARM Torque Converter F4SZ-7902-BRM Torque Converter Please use the following repair description for each model described in the OPERATION/DESCRIPTION/TIME section of this TSB article: Perform electronic transmission diagnostics, replace torque converter, drain and fill transmission (including inspection of filter - replace if necessary), flush cooler and lines. Road test vehicle after repairs are complete. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-14-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952304A 1994-95 Econoline 4.6 Hrs. 952304B 1994-95 F-Series 4X2 4.4 Hrs. 952304C 1994-95 F-Series 4X4 6.0 Hrs. 952304D 1994-95 Mustang 3.8L 5.1 Hrs. 952304E 1994-95 Mustang 5.0L 5.3 Hrs. 952304F 1994-95 5.4 Hrs. Thunderbird/Cougar 4.6L 952304G 1994-95 5.3 Hrs. Thunderbird/Cougar 3.8L 952304H 1993-95 Mark VIII 5.4 Hrs. 952304I 1992-95 Crown 4.9 Hrs. Victoria/Grand Marquis/Town Car DEALER CODING CONDITION BASIC PART NO. CODE 7902 67 OASIS CODES: 501000, 502000, 504000, 510000, 597997, 703000, 703200, 703400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips Transmission Cooler: Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 4693 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 4694 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 4695 Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 4696 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 4697 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 4698 Transmission Cooler: Testing and Inspection NOTE: The linkage, fluid and control pressure must be within specification before performing this flow check. 1. Remove transmission dipstick from filler tube, then place funnel in filler tube. 2. Raise and support vehicle, then remove cooler return line from its fitting in case. 3. Attach hose to cooler return line and fasten free end of hose to funnel installed in filler tube. 4. Start engine and set idle speed at 1000 RPM with transmission in NEUTRAL. 5. Observe fluid flow at funnel. When flow is solid, air bleeding has been completed, flow should be liberal. If there is not a liberal flow at 1000 RPM in NEUTRAL, low pump capacity, main circuit system leakage, or cooler system restriction is indicated. 6. To separate transmission trouble from cooler system trouble, observe flow at transmission case converter out fitting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power/Economy Mode Switch, A/T Transmission Mode Switch: Description and Operation Power/Economy Mode Switch, A/T Transmission Control Switch (TCS) DESCRIPTION The Transmission Control Switch (TCS) is a momentary contact switch which disables 4th gear operation and enables engine braking when activated. OPERATION When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM). The PCM then energizes the Transmission Control Indicator Lamp (TCIL) and the Coast Clutch Solenoid (CCS), applying the coast clutch to provide engine braking and cancels fourth gear operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power/Economy Mode Switch, A/T > Page 4703 Transmission Mode Switch: Description and Operation Transmission Mode Switch Transmission Control Switch (TCS) DESCRIPTION The Transmission Control Switch (TCS) is a momentary contact switch which disables 4th gear operation and enables engine braking when activated. OPERATION When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM). The PCM then energizes the Transmission Control Indicator Lamp (TCIL) and the Coast Clutch Solenoid (CCS), applying the coast clutch to provide engine braking and cancels fourth gear operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4708 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4709 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4710 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4711 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4712 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4713 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4714 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4715 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4716 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4717 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4718 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4719 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4720 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4721 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4722 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4723 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4724 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4725 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4726 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4727 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4728 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4729 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4730 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4731 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4732 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4733 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4734 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4735 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4736 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4737 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4738 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4739 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4740 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4741 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4742 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4743 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4744 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4745 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4746 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4747 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4748 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4749 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4750 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4751 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4752 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4753 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4754 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4755 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4756 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4757 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4758 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4759 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4760 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4761 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4762 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4763 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4764 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4765 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4766 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4767 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4768 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4769 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4770 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4771 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4772 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4773 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4774 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4775 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4776 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4777 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4778 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4779 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4780 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4781 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4782 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4783 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4784 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4785 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4786 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4787 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4788 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4789 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4790 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4791 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4792 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4793 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4794 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4795 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4796 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4797 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4798 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4799 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4800 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4801 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4802 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: Customer Interest A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission Transmission Position Switch/Sensor: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission > Page 4818 Transmission Position Switch/Sensor: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only > Page 4821 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission Transmission Position Switch/Sensor: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission > Page 4824 Transmission Position Switch/Sensor: Testing and Inspection With 4R70W Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Speed Sensor <--> [Transmission Speed Sensor, A/T] > Component Information > Locations Output Shaft Speed Sensor: Locations The Output Shaft Speed Sensor is located at the LH rear of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor PURPOSE Used as an input to determine shift schedule and Electronic Pressure Control (EPC) for temperature effects. DESCRIPTION The Transmission Fluid Temperature (TFT) sensor is a temperature-sensitive device called a thermistor it is located in the solenoid body assembly it sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with the transmission fluid temperature. OPERATION The PCM uses the voltage signal to determine whether a cold start shift schedule is necessary. The cold start shift schedule lowers shift speeds to allow for the reduced performance of cold engine operation. The TFT is part of the transmission solenoid assembly and is not replaced separately. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Vacuum Diaphragm, A/T > Component Information > Description and Operation Vacuum Diaphragm: Description and Operation DESCRIPTION Altitude Compensating Vacuum Diaphragm This unit, the Altitude Compensating Vacuum Diaphragm, is used in some transmissions. The unit incorporates an evacuated bellows that is sensitive to barometric pressure. OPERATION Barometric pressure decreases about 1 in Hg for each 1,000 ft altitude increase. The bellows decreases throttle pressure at higher altitude to make the shift feel comparable to lower altitude. The engine power loss at high altitude is offset by a lower throttle pressure and the shifts remain smooth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Vacuum Diaphragm, A/T > Component Information > Description and Operation > Page 4834 Vacuum Diaphragm: Testing and Inspection VACUUM DIAPHRAGM CHECK NOTE: To check the vacuum diaphragm for leakage, remove the unit from transmission. 1. Using a distributor tester equipped with a vacuum pump, set regulator knob so that vacuum gauge reads 18 in Hg with end of the vacuum hose blocked off. 2. If the diaphragm holds 18 in Hg of vacuum, the vacuum diaphragm is not leaking. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Vacuum Regulator Valve, A/T > Component Information > Description and Operation Vacuum Regulator Valve: Description and Operation DESCRIPTION Vacuum Regulator Valve The vacuum regulator valve is used on some models equipped with the 7.3L diesel engine to provide a vacuum signal which is proportional to throttle position. OPERATION A constant vacuum source is supplied to the vacuum regulator valve by an engine driven vacuum pump which also delivers vacuum to other accessories. The vacuum regulator valve regulates an output vacuum signal to the transmission's vacuum diaphragm. As the throttle is opened, regulated vacuum from the vacuum regulator valve decreases. In the event a malfunction should occur within the vacuum regulator valve, the valve will cause a zero (0) vacuum signal to be transmitted to the diaphragm which will cause delayed and harsh shifts to occur. Anytime delayed or harsh upshifts are encountered, the performance of the vacuum regulator valve should be checked prior to performing any transmission repairs. NOTE: Should the vacuum regulator valve be replaced or the fuel injection pump removed, the vacuum regulator valve must be adjusted. LOCATION The vacuum regulator valve is located on the fuel injection pump, and is actuated by the throttle lever. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Vacuum Regulator Valve, A/T > Component Information > Description and Operation > Page 4838 Vacuum Regulator Valve: Adjustments VACUUM REGULATOR VALVE ADJUST NOTE: During the check and adjustment procedure, the engine must not be operating. 1. Disconnect two port vacuum connector from vacuum regulator valve located on the left side of the fuel injection pump. 2. Disconnect throttle cable from throttle lever. 3. Remove throttle return spring. Install end of spring over throttle lever ball stud and other end of spring over throttle cable support bracket. 4. Connect a suitable vacuum pump to the upper port of the vacuum regulator valve (vacuum supply side). 5. Connect a suitable vacuum gauge to lower port of vacuum regulator valve labeled TRANS. 6. Apply and maintain 20 in Hg of vacuum to the vacuum regulator valve. It will be necessary to pump the vacuum up as it bleeds off. Cycle the throttle lever 5 times from idle to the wide open throttle position with vacuum applied. Vacuum Regulator Valve Gauge Block Installation 7. Insert gauge block No. T83T-7B200-AH (0.515 in) between pump boss and throttle wide open stop. The throttle return spring as repositioned previously, will hold the throttle lever stop against the gauge block tool. The vacuum gauge should indicate 6-8 in Hg of vacuum. If reading obtained is not as specified, adjust vacuum regulator valve as follows: a. Loosen two adjustment screws attaching vacuum regulator valve to the fuel injection pump. b. Rotate vacuum regulator valve until correct vacuum reading is obtained, then torque the two adjustment screws to 75-90 in lbs. c. If vacuum regulator valve cannot be adjusted, replace vacuum regulator valve and repeat adjustment procedure. d. Remove gauge block tool. e. Connect throttle return spring and throttle cable. f. Apply 20 in Hg of vacuum to the vacuum regulator valve and while maintaining vacuum, cycle throttle lever from idle to the wide open throttle position 5 times. The vacuum gauge should indicate at least 13 in Hg (throttle at idle position). g. If vacuum gauge indicates less than 13 in Hg the vacuum regulator valve must be replaced and the new valve adjusted. h. After necessary adjustment procedure has been completed, remove vacuum pump and gauge from vacuum regulator valve. Reconnect vacuum connector. i. Start engine and check operation of throttle. Check transmission shifts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Main Controls/Separator Plate/Gaskets Usage Valve Body: Technical Service Bulletins A/T - Main Controls/Separator Plate/Gaskets Usage Article No. 98-16-8 08/17/98 TRANSMISSION - E4OD/4R100 - 1989-99 - MAIN CONTROLS, SEPARATOR PLATES AND SEPARATOR PLATE GASKETS USAGE CHART LIGHT TRUCK: 1989-96 BRONCO, F-150 1989-97 F SUPER DUTY, F-250 HD 1989-98 ECONOLINE, F-250 LD, F-35O 1997-98 EXPEDITION, F-150 1998 NAVIGATOR 1999 SUPER DUTY F SERIES Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 4843 This TSB article is being republished in its entirety to revise Figure 1. ISSUE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Main Controls/Separator Plate/Gaskets Usage > Page 4844 The Chart has been developed to assist in showing the complexity and compatibility of main controls, separator plates, and plate gaskets used for E4OD/4R100 transmissions. ACTION Refer to the Usage Chart for information showing the compatibility of main controls, separator plates, and plate gaskets. This TSB should not be used in place of the Parts Catalog. NOTE TO VERIFY CORRECT GASKET USAGE, REFER TO FIGURE 1 TO IDENTIFY THE SEPARATOR PLATE I.D. NOTCHES. THEN REFER TO THE CHART TO SEE WHICH GASKETS ARE COMPATIBLE WITH THE MAIN CONTROLS AND SEPARATOR PLATES BEING USED. CAUTION MIXING COMPONENTS OTHER THAN THOSE LISTED MAY CAUSE SHIFT CONCERNS AND/OR DAMAGE TO THE TRANSMISSION. REFER TO THE PARTS CATALOG FOR PROPER USAGE BY MODEL AND YEAR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-9-21 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000, 590000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > With C6 Valve Body Details Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > With C6 > Page 4847 Check Ball Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Valve Body, A/T Valve Body: Description and Operation Valve Body, A/T Line Pressure Coasting Regulator and Boost Valves DESCRIPTION AND OPERATION The line pressure coasting valve has been redesigned and a new valve, the line pressure coasting regulator valve, has been added to the same bore. These valves provide improved line pressure coasting boost for greater torque holding ability at the intermediate band. Main Oil Pressure Boost Valve DESCRIPTION AND OPERATION The pressure boost valve is the same in construction and operation as the earlier boost valve except for operation during a manual shift from Drive range to 2 or 1 range. Manual Low 2-1 Scheduling Valve DESCRIPTION AND OPERATION This valve and spring are located in the bore that formerly housed the 3-2 coasting control valves. When governor pressure on the upper end of the valve drops to the appropriate value, 2-1 scheduling pressure together with spring force will force the D2 shift valve upwards, effecting a downshift. Manual Valve DESCRIPTION AND OPERATION One passage controls pressure to the manual valve. The valve is positioned by the manual linkage according to mode of operation desired. Primary Throttle Valve DESCRIPTION AND OPERATION The primary throttle valve generates throttle pressure in the same way as earlier models and at the same rate with respect to manifold vacuum. 1-2 Shift Valve Train DESCRIPTION AND OPERATION In construction and operation the 1-2 shift valve train is the same as the earlier transmission except that the spring end of the D2 valve is pressurized with manual 2-1 scheduling pressure during a 2-1 or 3-1 manual downshift rather than with line pressure as in the earlier transmission. 2-3 Backout Valve DESCRIPTION AND OPERATION The 2-3 backout valve is functionally the same as the earlier valve but is slightly different in appearance. The valve has been redesigned so that the spring is housed in the lower part of the valve. In addition, the lower end of the spring seats in a spring retainer, and a spring retainer clip retains the entire valve train in the bore. 2-3 Shift Orifice and Check Valve DESCRIPTION AND OPERATION When the manual lever is moved to 2 or 1 to force a 3-2 downshift, the 2-3 shift orifice check ball unseats to allow the release fluid to bypass the orifice and exhaust without further obstruction. 3-2 Shift Timing Valve DESCRIPTION AND OPERATION This valve moves in response to variations in governor pressure which is routed to the upper end of the valve. However, the valve is non-functional and its position does not affect the operation of the control assembly. With E4OD DESCRIPTION AND OPERATION The main control body assembly directs transmission fluid under pressure to the servo, clutches, and solenoids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Valve Body, A/T > Page 4850 Valve Body: Description and Operation Solenoid Body Transmission Solenoid Body Solenoid Operation Chart. PURPOSE The transmission solenoid body is used by the Powertrain Control Module (PCM) to Regulate Electronic Pressure Control (EPC) pressure, transmission shift points, and converter lock-up on the E4OD automatic transmission. OPERATION The PCM controls the E4OD transmission operation through four on/off solenoids and one Variable Force Solenoid. These solenoids and Transmission Oil Temperature (TOT) sensor are part of the transmission solenoid body and are not serviced individually. The TOT sensor is used by the PCM to monitor transmission temperature.The five solenoids are used to control EPC for transmission shift and converter lock-up control. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation With C6 REMOVAL 1. Raise car on hoist or jack stands. 2. Loosen and remove all but two oil pan bolts from front of case and drop rear edge of pan to drain fluid. Remove and clean pan and screen. NOTE: Remove and discard the nylon shipping plug from the filler tube hole. 3. Unfasten and remove valve body. INSTALLATION 1. Position valve body to case, making sure that selector and downshift levers are engaged, then install and torque attaching bolts to 95-125 in lbs. 2. Using a new pan gasket secure pan to case and torque bolts to 8-12 ft lbs. 3. Lower car and fill transmission to the correct level with specified fluid. With E4OD REMOVAL NOTE: The valve body and the intermediate band servo are replaced as an assembly. 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Loosen oil pan attaching bolts and drain fluid from transmission, then remove attaching bolts and pan. 4. Remove filter and gasket. Main Control Body Removal 5. Remove accumulator body and main control body attaching bolts. NOTE: Do not remove two bolts, as shown in the Main Control Body Removal image, from main control body. 6. Remove solenoid body attaching bolts. Remove solenoid body by pushing down on solenoid body receptacle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4853 Solenoid Screen Removal 7. Remove solenoid screen by turning counterclockwise and pulling out, as shown in the Solenoid Screen Removal image. 8. Remove three reinforcing plate attaching bolts, then the plate. 9. Carefully lower separator plate and gasket so check balls, Electronic Pressure Control (EPC) ball and spring are retained. Intermediate Band Servo Assembly Removal 10. Remove servo snap ring and retaining plate, piston, rod assembly, and servo spring. INSTALLATION 1. Reverse procedure to install, noting the following: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4854 Check Ball Locations a. Ensure same number of check balls, EPC ball and spring are in proper position. b. Torque reinforcing plate, main control body, accumulator body, and solenoid body attaching bolts to 80-100 in lbs. c. Torque pan bolts to 10-12 ft lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4855 Valve Body: Service and Repair Disassembly and Assembly With C6 DISASSEMBLY CAUTION: All parts must be handled carefully to avoid nicking or burring the bearing or mating surfaces. Lubricate all internal parts with clean automatic transmission fluid before assembling them. Do not use any other lubricants except on gaskets and thrust washers. These may be coated with petroleum jelly to facilitate assembly. Always use new gaskets and seals when assembling transmission. Upper And Lower Valve Bodies Disassembled 1. Remove screen from lower valve body. 2. Separate upper and lower valve bodies, and remove separator plate and gasket. 3. Remove manual valve retaining pin from upper valve body. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4856 Upper Valve Body Disassembled, (Gasoline Engine) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4857 Upper Valve Body Disassembled, (Diesel Engine) 4. Slide manual valve out of body. 5. Cover downshift valve port with a finger. Then, working from underside of body, remove downshift valve retainer. Remove spring and downshift valve. 6. Apply hand pressure on pressure booster valve retaining plate and remove two screws. Slowly release pressure and remove plate, sleeve and pressure booster valve. Remove two springs and main regulator valve from same bore. 7. Apply pressure on throttle booster valve retaining plate and remove two screws. Slowly release pressure and remove plate, throttle boost valve and spring, and the manual low 2-1 scheduling valve and spring from the body. 8. Apply pressure on remaining valve retaining plate and remove eight screws. 9. Hold valve body so that plate is facing upward. Slowly release pressure and remove plate. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4858 10. When removing various valves from valve body, keep all parts covered with your finger except the bore the valve is being removed from. Remove the 1-2 shift capacity scheduling and accumulator valves and springs, as shown in the Exploded View Of Upper Valve Body images. 11. Remove 2-3 backout valve and spring. Do not remove the 3-2 shift timing valve plug (manual low valve) if it is peened, preventing its removal. This condition will not affect transmission operation and is not cause for valve body replacement. 12. Remove 2-3 shift valve, spring, and throttle modulator valve. 13. Remove 1-2 shift valve, D2 shift valve and spring. 14. Remove coasting boost valve and spring. 15. Remove cut back control valve to complete the disassembly of the control valve. ASSEMBLY Valve Body Details 1. Reverse procedure to assemble the control valve. During the procedure, place the converter relief valve spring in its bore. Coat the check ball with petroleum jelly and place it on top of the spring. Place the 2-3 check ball in its cavity. Torque all screws and bolts. With E4OD Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4859 Exploded View Of Valve Body And Accumulator Valve Body, (Part 1 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4860 Exploded View Of Valve Body And Accumulator Valve Body, (Part 2 Of 2) NOTE: Refer to the Exploded View Of Valve Body And Accumulator Valve Body image during disassembly and assembly procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection Differential Case: Testing and Inspection 1. Apply a suitable multi-purpose long-life lubricant to side gear thrust washers, hub, thrust face of side gears, pinion mate gears and spherical washers. 2. Hold side gears in place in case, then install pinion mate gears and spherical washers. 3. Rotate side gears until holes in washers and pinion mate gears align with holes in case. NOTE: If gears cannot be rotated by hand, install an axle shaft into side gear spline and use a pipe wrench to turn shaft. 4. Use a drift to align holes, then insert pinion mate shaft and drive into case to remove drift, ensuring lockpin hole in shaft aligns with lockpin holes in case. 5. Insert lockpin, then peen some metal of case over pin to lock it into place. The semi-float shaft riding bearing design uses a lockpin that is installed using a 12 point socket. Use a new lockpin and assemble finger tight. This prevents differential side gears and differential pinion mate gears from rotating inside case and dropping out when servicing the carrier section. NOTE: A new lockpin should be installed after assembling the axle shafts. 6. If applicable, install exciter ring as follows: a. Align tab in exciter ring with slot in differential case, then thread two ring gear bolts through case into ring gear to ensure bolt hole alignment. Tab on exciter ring must be aligned with slot in differential case. b. Press exciter ring and ring gear onto differential case. Ring gear acts as a pilot for exciter ring. c. Apply threadlock and sealer part No. E0AZ-19554-AA, or equivalent, to new ring gear bolts. 7. Attach ring gear to differential case using new bolts, then tighten bolts alternately and evenly. 8. Clean trunnions on differential and install bearings onto differential case. Remove all burrs and nicks from hubs so bearings rotate freely. Fig. 10 Total Differential Case Endplay Inspection 9. Place differential case into carrier (without pinion). Differential case should move freely in carrier assembly. Position a suitable dial indicator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Page 4865 against differential case flanges. Locate tip of indicator on flat surface of one ring gear bolt. Force differential case toward dial indicator as far as possible and zero dial indicator with force still applied. Dial indicator should have a minimum of 0.200 inch. Force differential case away from dial indicator as far as it will go. Repeat this procedure until same reading is obtained. Record dial indicator reading as measurement "A on a work sheet for calculating ring gear backlash and differential bearing preload shims. This reading indicates amount of shims needed behind differential side bearings to take up total clearance between differential bearing cup and carrier. This reading will be used during a Pinion & Ring Gear Backlash Inspection. 10. Remove differential case from carrier. Do not remove differential case bearings at this time. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal Differential Case: Service and Repair Removal NOTE: When changing ratios on Model 60 and 70 series axles, it may be necessary to change the differential case, ring gear and drive pinion. Fig. 3 Exploded View Of Model 61-1U, 70-1Hd & 70-2U Full-floating Rear 1. Remove axle assembly from vehicle. See: Differential Axle Housing/Service and Repair 2. Remove axle shafts. 3. Remove cover plate and drain lubricant, then clean all gasket surfaces. 4. Remove bearing caps. Note matched numbers or letters stamped on the cap and carrier assembly. These numbers or letters must be matched during assembly. These numbers may either be stamped vertically, horizontally or, in some instances, both vertically and horizontally. 5. Mount spreader tool No. 4000-E, or equivalent, onto carrier assembly. 6. Position a dial indicator onto carrier, then spread housing. CAUTION: Do not spread housing more than 0.015 inches. 7. Remove differential case from carrier. It may be necessary to pry case from carrier with suitable pry bars. Use care to avoid damaging machined surfaces. 8. Remove and tag bearing cups to indicate which side of carrier they were removed from, then remove spreader tool from case. NOTE: Models 60 and 70 series axles use spacers installed outboard of each bearing cup, remove and tag for reference during assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal > Page 4868 Differential Case: Service and Repair Subassembly Service Dana/Spicer Model 60-1U DISASSEMBLE 1. Place one axle shaft in vise, splined end up, so that splines do not extend more than three inches above jaws of vise. 2. Mount differential case on axle shaft. Fig. 7 Exploded View Of Trac-Lok Locking Differential. 3. Using suitable drift, remove roll pin retaining cross pin, then drive out cross pin with hammer and suitable drift. 4. Position step plate into bottom side gear and lubricate centering hole of step plate. 5. Position gear rotating tool into top side gear. 6. Lubricate threads of forcing screw and thread screw into gear rotating tool, guiding forcing screw into step plate. 7. Tighten forcing screw securely, then, using a piece of 0.030 inch shim or gauge stock, push out differential spherical washers. 8. Loosen forcing screw momentarily, then tighten forcing screw until a very slight movement of the differential pinion gears is seen. 9. Slide pawl of gear rotating tool between two side gear teeth and pull handle so top side gear rotates, rotating differential pinion gears. Remove differential pinion gears through large openings in case. NOTE: When attempting to rotate side gear, it may be necessary to tighten or loosen forcing screw to permit gear movement. 10. Manually hold top side gear and clutch pack in case and remove forcing screw, then the gear rotating tool. 11. Remove top side gear and clutch pack, keeping plates and discs in exact order. 12. Turn case so that ring gear side faces up, easing step plate, side gear, and clutch pack out of case. 13. Remove retainer clips from clutch packs, keeping discs and plates in exact order. ASSEMBLE 1. Install side gears and thrust washers in correct order. 2. Lubricate thrust face of side gear and plates and discs with suitable lubricant and assemble plates and discs to side gear splines. 3. Assemble retainer clips to ears of plates, ensure clips are completely assembled or seated onto ears of plates. 4. Assemble clutch pack and side gear into case, ensure clutch pack stays assembled to side gear splines and that retainer clips are completely seated into pockets of case. 5. Manually retain clutch pack in case, position case on bench, and assemble step plate into side gear, applying small amount of lubricant into centering hole of step plate. 6. Assemble remaining clutch pack and side gear, ensure clutch pack stays assembled to side gear splines and that retainer clips are completely seated into pockets of case. 7. Position gear rotating tool into top side gear, manually hold side gear and rotating tool in position, insert forcing screw down through top of case, and thread screw into rotating tool until screw contacts step plate. 8. Position case onto axle shaft by aligning splines of side gear with splines of shaft. 9. Position differential pinion gears opposite one another through openings in case, ensure holes of gears are aligned, manually retain gears in position, and tighten forcing screw so that side gears move away from differential pinion gears. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal > Page 4869 10. Hold differential pinion gears in place and insert pawl of rotating tool between two side gear teeth, then pull on handle so that top side gear rotates and allows differential pinion gears to rotate and enter into case. NOTE: It may be necessary to slightly tighten or loosen forcing screw to permit gear movement. 11. Put on tool until handle hits case, then remove pawl from between gear teeth and position handle and pawl. Repeat this step until holes of differential pinion gears are perfectly aligned with holes of case. 12. Lubricate both sides of pinion spherical washers with suitable lubricant. 13. Tighten forcing screw to obtain installation clearance for spherical washers. 14. Install spherical washers, ensure holes of washers and gears are perfectly aligned with holes of case, then remove forcing screw, rotating tool, and step plate. 15. Install pinion shaft in differential case, then the cross shaft locking pin. Dana/Spicer Model 70-1HD, 70-2U DISASSEMBLE 1. Scribe a mark between the differential case halves to be used during assembly. Also, mark the pinion mate shafts and corresponding ramps for assembly in original locations. 2. Clamp differential assembly in a soft jaw vise. Fig. 6 Exploded View Of Powr-Lok Locking Differential. 3. Loosen but do not remove the case half retaining bolts. 4. Place assembly on bench with the ring gear half down and remove case half retaining screws. 5. Remove the cover half of the case. 6. Remove upper mate shaft, side gear, side gear ring and clutch pack. Retain parts with cover half of case so they can be installed in original position. 7. Remove lower mate shaft, side gear, side gear ring and clutch pack from drive gear case half. ASSEMBLE 1. Place side gear ring from ring gear half of case on a pinion flange or other suitable fixture so the case is approximately four inches above bench. 2. Lubricate clutch plates and assemble clutch pack on side gear ring. 3. Place ring gear side of case over clutch pack and side gear ring. Ensure the clutch plate lugs enter the slots in the case and that the case bottoms on the clutch pack. 4. Invert the assembly. Hold assembly together while inverting. 5. Install the ring gear case half side gear in side gear ring. 6. Install axle shaft spacer in cross shaft. 7. Install the ring gear case half pinion mate shaft and pinions on the side gear ring. 8. Install the cover half pinion mate shaft and pinions. 9. Place side gear on pinions, then the side gear ring on side gear. 10. Assemble clutch pack on side gear ring, aligning clutch pack lugs. 11. Install cover half of case over assembly, aligning the marks made during disassembly. 12. Install the case half retaining bolts, turning the bolts to engage a few threads only. 13. Insert axle shaft into assembly and align the splines of the side gears and side gear rings. With the axle shafts in position, tighten case half retaining bolts to specifications. 14. Remove axle shafts. 15. If the differential has been assembled properly, each pinion mate cross shaft should be tight on its ramp. However, if clearance is present, it should not exceed 0.010 inch and be equal at all four cross shaft ends. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Dana/Spicer Model 60-1U (Full-Floating Axle) Differential Cover: Specifications Dana/Spicer Model 60-1U (Full-Floating Axle) Cover Bolts .......................................................................................................................................... ............................................................. 30-40 ft lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Dana/Spicer Model 60-1U (Full-Floating Axle) > Page 4874 Differential Cover: Specifications Dana/Spicer Model 60-1U (Semi-Floating Axle) Cover Bolts .......................................................................................................................................... ................................................................. 30-40 ft lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Dana/Spicer Model 60-1U (Full-Floating Axle) > Page 4875 Differential Cover: Specifications Dana/Spicer Model 70-1HD Cover Bolts .......................................................................................................................................... ................................................................. 30-40 ft lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Dana/Spicer Model 60-1U (Full-Floating Axle) > Page 4876 Differential Cover: Specifications Dana/Spicer Model 70-2U Cover Bolts .......................................................................................................................................... ................................................................. 30-40 ft lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair Differential Axle Housing: Service and Repair REMOVAL AND INSTALLATION 1. Raise and support vehicle. 2. Remove rear wheels and brake drums. 3. Remove rear wheel bearing retainer plate attaching nuts. 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. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications TYPE: Standard 80W-90 GL-5 F150/4.10:1 axle ratio and Lightning Pickup, rear synthetic 75W-140 GL-5 Limited-Slip 80W-90 GL-5* LIMITED-SLIP OR TRACTION-LOK IDENTIFICATION: Label on door lock pillar shows letter and number CAPACITY, Refill: Rear: Ford w/8.8" ring gear 5.5 pt (US) 8.8" & 10-1/4" has removable cover. Fill 1/4" to 9/16" below fill hole w/10-1/4" ring gear 6.5 pt (US) 8.8" & 10-1/4" has removable cover Dana 60-IU 6.3 pt (US) Fill Dana axles 1/4" to 3/4" below fill hole Dana 70 except HD 6.5 pt (US) Fill Dana axles 1/4" to 3/4" below fill hole Dana 70 7.4 pt (US) Fill Dana axles 1/4" to 3/4" below fill hole Dana 80 8.3 pt (US) Fill Dana axles 1/4" to 3/4" below fill hole Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4884 Fluid - Differential: Fluid Type Specifications KEY TO LUBRICATION ABBREVIATIONS NOTE: Some manufacturer lubricant names may differ from the following list. If the manufacturer does not recommend a specific lubricant, use the following. AF Dexron(r)-III Automatic Transmission Fluid AP ATF-PLUS(r) Automatic Transmission Fluid BJ Suspension Lubricant BL Brake Lubricant CC Motor Oil, API Service CC CD Motor Oil, API Service CD CE Motor Oil, API Service CE CF-4 Motor Oil, API Service CF-4 DC Distributor Cam Lubricant EC Ethylene Glycol Coolant EP Extreme Pressure Gear Oil FA Automatic Transmission Fluid, Type F GC Wheel Bearing Grease, NLGI Classification GC GF-1 Motor Oil, API Service GF-1 (Starburst) GL-1 Gear Oil, API Service GL-1 GL-4 Gear Oil, API Service GL-4 GL-5 Gear Oil, API Service GL-5 GL-5* GL-5 Gear Oil for Limited Slip Differentials GLS Gear Lubricant, Special HB Hydraulic Brake Fluid, SAE J1703, DOT-3 or 4 HBH Hydraulic Brake Fluid, Extra Heavy Duty HG High Temperature Grease HP Hypoid Gear Oil HP* Hypoid Gear Oil for Limited Slip or Traction-Lok Differentials LB Chassis Grease, NLGI Classification LB LL Steering Linkage Lubricant LM Lithium Multipurpose Grease LS Steering Gear Lubricant MA Mercon(r) Automatic Transmission Fluid MH Manifold Heat Riser Solvent MO Motor Oil, Any API Service Classification PC Carburetor Cleaner PS Power Steering Fluid SF Motor Oil, API service SF SG Motor Oil, API service SG SH Motor Oil, API service SH SLF Special Lubricant - Fluid SLS Special Lubricant - Spray WB Wheel Bearing Grease Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Measurement Specification Pinion Bearing: Specifications Measurement Specification Dana/Spicer Model 60-1U (Full-Floating Axle) PINION BEARING PRELOAD Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings [1] ....................................... .............................................................................................................................. 20-40 Inch Pounds [1] Rotational torque. Dana/Spicer Model 60-1U (Semi-Floating Axle) PINION BEARING PRELOAD Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings [1] ....................................... .............................................................................................................................. 20-40 Inch Pounds [1] Rotational torque. Dana/Spicer Model 70-1HD PINION BEARING PRELOAD Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings [1] ....................................... .............................................................................................................................. 20-40 Inch Pounds [1] Rotational torque. Dana/Spicer Model 70-2U PINION BEARING PRELOAD Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings [1] ....................................... .............................................................................................................................. 20-40 Inch Pounds [1] Rotational torque. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Measurement Specification > Page 4889 Pinion Bearing: Specifications Torque Specification Dana/Spicer Model 60-1U (Full-Floating Axle) PINION NUT TO DRIVE PINION Pinion Shaft Nut ................................................................................................................................... ........................................................ 250-270 ft lb Dana/Spicer Model 60-1U (Semi-Floating Axle) PINION NUT TO DRIVE PINION Pinion Shaft Nut ................................................................................................................................... ........................................................ 250-270 ft lb Dana/Spicer Model 70-1HD PINION NUT TO DRIVE PINION Pinion Shaft Nut ................................................................................................................................... ........................................................ 250-270 ft lb Dana/Spicer Model 70-2U PINION NUT TO DRIVE PINION Pinion Shaft Nut ................................................................................................................................... ........................................................ 250-270 ft lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Page 4890 Pinion Bearing: Service and Repair Fig. 14 Inner & Outer Pinion Cup Installation Tools 1. Place inner and outer pinion bearing cups into carrier bore. 2. Place suitable inner and outer bearing cup replacer tools on their respective cups. 3. Install a suitable threaded draw bar into replacer tools and tighten drawbar to install cups in their bores. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Measurement Specification Pinion Gear: Specifications Measurement Specification Dana/Spicer Model 60-1U (Full-Floating Axle) RING GEAR & PINION BACKLASH Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings [1] ....................................... ............................................................................................................................... 0.005 - 0.008 Inch [1] Measurements taken at three different points cannot vary more than 0.003 inch. Dana/Spicer Model 60-1U (Semi-Floating Axle) RING GEAR & PINION BACKLASH Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings [1] ....................................... ............................................................................................................................... 0.005 - 0.008 Inch [1] Measurements taken at three different points cannot vary more than 0.003 inch. Dana/Spicer Model 70-1HD RING GEAR & PINION BACKLASH Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings [1] ....................................... ............................................................................................................................... 0.005 - 0.008 Inch [1] Measurements taken at three different points cannot vary more than 0.003 inch. Dana/Spicer Model 70-2U RING GEAR & PINION BACKLASH Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings [1] ....................................... ............................................................................................................................... 0.005 - 0.008 Inch [1] Measurements taken at three different points cannot vary more than 0.003 inch. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Measurement Specification > Page 4895 Pinion Gear: Specifications Torque Specification Dana/Spicer Model 60-1U (Full-Floating Axle) PINION NUT TO DRIVE PINION Pinion Shaft Nut ................................................................................................................................... ........................................................ 250-270 ft lb Dana/Spicer Model 60-1U (Semi-Floating Axle) PINION NUT TO DRIVE PINION Pinion Shaft Nut ................................................................................................................................... ........................................................ 250-270 ft lb Dana/Spicer Model 70-1HD PINION NUT TO DRIVE PINION Pinion Shaft Nut ................................................................................................................................... ........................................................ 250-270 ft lb Dana/Spicer Model 70-2U PINION NUT TO DRIVE PINION Pinion Shaft Nut ................................................................................................................................... ........................................................ 250-270 ft lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Testing and Inspection > Depth Gauge Inspection Pinion Gear: Testing and Inspection Depth Gauge Inspection Fig. 15 Depth Gauge Tool Selection NOTE: It is important to use the correct tools for particular axle assemblies. If any gauge surfaces become nicked, high spots must be removed with a medium India oilstone to ensure no erroneous readings. 1. Place a new inner pinion bearing over proper aligning adapter and insert into pinion bearing retainer assembly. Place outer pinion bearing into bearing cup in carrier and assemble handle onto screw and hand tighten. Note 3/8 inch square drive in handle to be used for obtaining proper pinion bearing preload. To preload bearings, Torque handle to 20-40 inch lb. 2. Center proper gauge tube into differential bearing bore, install bearing caps and tighten to specifications. 3. Using suitable feeler gauges, select thickest feeler gauge that will enter between gauge tube and gauge block. Insert feeler gauge directly along gauge block to ensure a correct reading. Feeler gauge fit between gauge tube and gauge block should be a slight drag-type feeling. 4. After correct feeler gauge feel is obtained, thickness of feeler gauge used to obtain slight drag-type feel is the thickness of shims required, provided new pinion gear is marked with a zero (0). If new pinion gear is marked with a plus (+) reading, the plus (+) amount stamped on pinion gear must be subtracted from thickness dimension obtained in preceding step. If new pinion gear is marked with a minus (-) reading, the minus (-) amount stamped on pinion gear must be added to thickness dimension obtained in preceding step. Also, you must use exact same new inner pinion bearing that was used to obtain this dimension. 5. Remove inner pinion bearing cup and install correct thickness of shims into carrier bore, then reinstall bearing cup and oil slinger and/or baffle, if required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Testing and Inspection > Depth Gauge Inspection > Page 4898 Fig. 16 Bearing Installation On Drive Pinion 6. Press bearing onto pinion. If a baffle and/or slinger is used, replace with a new one upon assembly and measure as part of the shim stack. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Testing and Inspection > Depth Gauge Inspection > Page 4899 Pinion Gear: Testing and Inspection Preload Inspection 1. Assemble preload shims and slinger, if applicable, onto pinion, then install pinion gear into carrier housing. 2. Install outer pinion bearing and oil slinger, if applicable. 3. Install end yoke or flange, washer and new pinion nut on pinion shaft and tighten to 250-270 ft lb. 4. Place an inch-pound torque wrench on pinion nut and check pinion rotational tightening. Rotational torque should be 20-40 inch lb. 5. To increase preload, remove shims. To decrease preload, add shims. 6. With drive pinion at correct preload, remove pinion nut, washer and end yoke or flange. 7. Coat drive pinion oil seal with suitable hypoid gear lubricant or equivalent, then install drive pinion oil seal using suitable oil seal replacer. After installation, ensure garter spring did not pop out. If garter spring pops out, remove and replace seal. 8. Install end yoke or flange with a suitable pinion flange replacer, then the washer and nut and tighten to 250-270 ft lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Testing and Inspection > Depth Gauge Inspection > Page 4900 Pinion Gear: Testing and Inspection Pinion & Ring Gear Backlash Inspection Fig. 10 Total Differential Case Endplay Inspection 1. Place differential case into position in carrier (differential case bearings should still be installed). 2. Force differential case away from drive pinion gear until it is completely seated against cross bore face of carrier. Position a dial indicator so indicator tip rests on a ring gear bolt head. Zero the dial indicator. 3. Force ring gear against pinion gear. Rock ring gear slightly to ensure gear teeth are in contact, then force ring gear away from pinion gear, ensuring dial indicator returns to zero. Repeat this procedure until dial indicator reading is the same. This reading should be recorded as measurement "B" and reveals amount of shims necessary between differential case and differential bearing on ring gear side. 4. Assemble shim pack for ring gear side to measurement "B." 5. Subtract measurement "B" from measurement "A" obtained in "Differential Case Endplay Inspection" See: Differential Case/Testing and Inspection to obtain measurement "C." Measurement "C" equals amount of shims required between differential case and bearing on side opposite of ring gear. 6. Assemble shim pack for side opposite of ring gear to measurement "C" plus (+) 0.015 in. 7. Remove differential case from carrier, then the bearings from case. 8. Place required amount of shims on hub of ring gear side of differential case, then install bearing and drive bearing onto hub using a suitable differential side bearing replacer. 9. Place required amount of shims on hub of differential case opposite of ring gear side, then install bearing. Place a suitable step plate on ring gear side bearing to protect bearing, then drive bearing opposite of ring gear side onto hub using differential side bearing replacer. 10. Install differential bearing cups onto bearings. 11. Mount spreader tool No. 4000-E and tool No. T80T-4000-B, or equivalents, onto carrier assembly. 12. Position a dial indicator onto carrier, then spread housing. Do not spread housing more than 0.015 in. 13. Install differential case into carrier. If necessary, use a rawhide or plastic hammer to seat case in carrier bore. With partial and non-hunting/partial ring gear and pinion sets, align marks on ring gear and drive pinion, if applicable. Use care not to nick teeth of ring gear or pinion. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Testing and Inspection > Depth Gauge Inspection > Page 4901 14. Remove spreader and dial indicator. 15. Install bearing caps and bolts, ensuring letters or numbers stamped on caps correspond in both position and direction with letters or numbers stamped into carrier, then tighten bolts to 80-90 ft lb. Fig. 17 Ring Gear & Pinion Backlash Inspection 16. Install dial indicator on case. 17. Check ring gear and pinion backlash at three equally spaced points on ring gear. Backlash tolerance is 0.005-0.009 inch and cannot vary more than 0.003 inch between the three points. 18. If backlash is high, ring gear must be moved closer to pinion by moving shims to ring gear side from opposite side. 19. If backlash is low, ring gear must be moved away from pinion by moving shims from ring gear side to opposite side. 20. Install new cover gasket and cover plate, then the mounting bolts and tighten to 30-40 ft lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Testing and Inspection > Page 4902 Pinion Gear: Adjustments Two separate adjustments affect drive pinion and ring gear tooth contact: pinion depth and pinion to ring gear backlash. Pinion depth is controlled by a pinion locating shim pack installed between drive pinion inner bearing cup and carrier housing. This shim pack and inner oil slinger controls the position of the pinion. Adding shims moves pinion toward ring gear and removing shims moves pinion away from ring gear. Pinion to ring gear backlash is controlled by preload shims located between the differential bearing cup and carrier. Fig.11 Ring & Pinion Identification On the button of each drive pinion is marked a plus (+), a minus (-) or a zero (0). These markings indicate the position for each gear set. The position is determined by amount of shims between inner pinion bearing cup and carrier bearing bore. Any pinion depth change is made by changing amount of shims. If the original gear set is being reused, measure the slinger and each shim separately and add each shim measurement to total original measurement. Replace old shims with new shims that equal this measurement, if necessary. Fig. 12 Drive Pinion Adjusting Shim Thickness chart (English) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Testing and Inspection > Page 4903 Fig. 13 Drive Pinion Adjusting Shim Thickness Chart (Metric) If a new gear set is being used, notice the plus (+), minus (-) or zero (0) etchings on both original and new drive pinion and add or subtract shims according to charts to compensate for differences between old and new pinion. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Testing and Inspection > Page 4904 Pinion Gear: Service and Repair NOTE: When changing ratios on Model 60 and 70 series axles, it may be necessary to change the differential case, ring gear and drive pinion. Fig. 3 Exploded View Of Model 61-1U, 70-1Hd & 70-2U Full-floating Rear 1. Remove axle assembly from vehicle. See: Differential Axle Housing/Service and Repair 2. Remove axle shafts. 3. Remove cover plate and drain lubricant, then clean all gasket surfaces. 4. Remove bearing caps. Note matched numbers or letters stamped on the cap and carrier assembly. These numbers or letters must be matched during assembly. These numbers may either be stamped vertically, horizontally or, in some instances, both vertically and horizontally. 5. Mount spreader tool No. 4000-E, or equivalent, onto carrier assembly. 6. Position a dial indicator onto carrier, then spread housing. CAUTION: Do not spread housing more than 0.015 inches. 7. Remove differential case from carrier. It may be necessary to pry case from carrier with suitable pry bars. Use care to avoid damaging machined surfaces. 8. Remove and tag bearing cups to indicate which side of carrier they were removed from, then remove spreader tool from case. NOTE: Models 60 and 70 series axles use spacers installed outboard of each bearing cup, remove and tag for reference during assembly. 9. Remove differential case bearings from case using tool No. D81L-4220-A, or equivalent. Place tool in a vise when removing bearing. Turn case over and remove other bearing in the same manner. 10. Wire shims, bearing cup, bearing, and spacer, if applicable, together and identify from which side of differential case they were removed. If any shims are damaged, replace with new shims. It is recommended that bearings be replaced. 11. Place a few shop towels over a vise to prevent ring gear teeth from being nicked after it is free from case assembly. Remove ring gear bolts, leaving four bolts loosely assembled 90 degrees apart. Tap each bolt head alternately with a rawhide or plastic hammer to loosen ring gear from case. Remove case and ring gear from vise. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Testing and Inspection > Page 4905 NOTE: If applicable, use care not to damage exciter ring when removing ring gear. Whenever removing ring gear bolts, discard and replace with new bolts upon assembly. 12. If applicable or necessary, remove exciter ring using a soft faced hammer, then discard ring. 13. Replace differential case in vise, then drive out lockpin that retains pinion mate shaft to case. 14. Remove pinion mate shaft using a suitable drift, then rotate side gears until pinion mate gears turn to opening of case. 15. Remove pinion mate gears and spherical washers behind gears, then lift out side gears and thrust washers. 16. Inspect all parts, including machined surfaces of case. If any one of gears are to be replaced, they are to be replaced as a set. NOTE: If excessive wear is visible on all parts, it is suggested that complete differential case assembly be replaced. 17. Turn nose of carrier upward, hold end yoke or flange with a suitable pinion flange holding tool, then remove pinion nut and washer from pinion shaft. 18. Remove end yoke or flange using a suitable yoke remover and inspect. If yoke or flange shows any signs of wear, replace. Fig. 5 Exploded View Of Pinion Preload Spacer & Shims. Model 70 Type Full-floating Rear Axle 19. Remove drive pinion by tapping on drive pinion shaft using a rawhide or plastic hammer. Catch pinion to prevent damage to pinion teeth. On spline end of pinion there are bearing preload shims. Collect shims and keep together for reassembly. NOTE: Model 70 axles may also use a pinion preload spacer with preload shims, preload spacer must be assembled in sequence or unit failure may occur. WARNING: Gear teeth may have sharp edges, use care when handling gear to prevent personal injury. 20. Remove drive pinion oil seal from carrier using a suitable bearing cup puller and a slide hammer. 21. Remove outer pinion bearing cone and outer oil slinger. 22. Turn nose of carrier downward and remove outer pinion bearing cup using a suitable pinion bearing cup remover and driver handle. Locate driver on back edge of cup and drive cup out of bore. 23. Remove inner pinion bearing cup and baffle using a suitable pinion bearing cup remover and driver handle. Shims are located between bearing cup and carrier bore and may also include an oil baffle. If shims and/or baffle are bent or nicked, replace. Wire shim stacks together and measure each. If stack has to be replaced, replace with same thickness. 24. Remove inner pinion bearing from drive pinion using tool No. D81L-4220-A, or equivalent. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Measurement Specification Ring Gear: Specifications Measurement Specification Dana/Spicer Model 60-1U (Full-Floating Axle) RING GEAR & PINION BACKLASH Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings [1] ....................................... ............................................................................................................................... 0.005 - 0.008 Inch [1] Measurements taken at three different points cannot vary more than 0.003 inch. Dana/Spicer Model 60-1U (Semi-Floating Axle) RING GEAR & PINION BACKLASH Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings [1] ....................................... ............................................................................................................................... 0.005 - 0.008 Inch [1] Measurements taken at three different points cannot vary more than 0.003 inch. Dana/Spicer Model 70-1HD RING GEAR & PINION BACKLASH Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings [1] ....................................... ............................................................................................................................... 0.005 - 0.008 Inch [1] Measurements taken at three different points cannot vary more than 0.003 inch. Dana/Spicer Model 70-2U RING GEAR & PINION BACKLASH Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings [1] ....................................... ............................................................................................................................... 0.005 - 0.008 Inch [1] Measurements taken at three different points cannot vary more than 0.003 inch. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Measurement Specification > Page 4910 Ring Gear: Specifications Torque Specification Dana/Spicer Model 60-1U (Full-Floating Axle) RING GEAR TO DIFFERENTIAL CASE Ring Gear Bolts (Grade 8) ................................................................................................................... ......................................................... 100-120 ft lb Ring Gear Bolts (Grade 9) .................................... ........................................................................................................................................ 125-135 ft lb Dana/Spicer Model 60-1U (Semi-Floating Axle) RING GEAR TO DIFFERENTIAL CASE Ring Gear Bolts (Grade 8) ................................................................................................................... ......................................................... 100-120 ft lb Ring Gear Bolts (Grade 9) .................................... ........................................................................................................................................ 125-135 ft lb Dana/Spicer Model 70-1HD RING GEAR TO DIFFERENTIAL CASE Ring Gear Bolts (Grade 8) ................................................................................................................... ......................................................... 100-120 ft lb Ring Gear Bolts (Grade 9) .................................... ........................................................................................................................................ 125-135 ft lb Dana/Spicer Model 70-2U RING GEAR TO DIFFERENTIAL CASE Ring Gear Bolts (Grade 8) ................................................................................................................... ......................................................... 100-120 ft lb Ring Gear Bolts (Grade 9) .................................... ........................................................................................................................................ 125-135 ft lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Page 4911 Ring Gear: Service and Repair NOTE: When changing ratios on Model 60 and 70 series axles, it may be necessary to change the differential case, ring gear and drive pinion. Fig. 3 Exploded View Of Model 61-1U, 70-1Hd & 70-2U Full-floating Rear 1. Remove axle assembly from vehicle. See: Differential Axle Housing/Service and Repair 2. Remove axle shafts. 3. Remove cover plate and drain lubricant, then clean all gasket surfaces. 4. Remove bearing caps. Note matched numbers or letters stamped on the cap and carrier assembly. These numbers or letters must be matched during assembly. These numbers may either be stamped vertically, horizontally or, in some instances, both vertically and horizontally. 5. Mount spreader tool No. 4000-E, or equivalent, onto carrier assembly. 6. Position a dial indicator onto carrier, then spread housing. CAUTION: Do not spread housing more than 0.015 inches. 7. Remove differential case from carrier. It may be necessary to pry case from carrier with suitable pry bars. Use care to avoid damaging machined surfaces. 8. Remove and tag bearing cups to indicate which side of carrier they were removed from, then remove spreader tool from case. NOTE: Models 60 and 70 series axles use spacers installed outboard of each bearing cup, remove and tag for reference during assembly. 9. Remove differential case bearings from case using tool No. D81L-4220-A, or equivalent. Place tool in a vise when removing bearing. Turn case over and remove other bearing in the same manner. 10. Wire shims, bearing cup, bearing, and spacer, if applicable, together and identify from which side of differential case they were removed. If any shims are damaged, replace with new shims. It is recommended that bearings be replaced. 11. Place a few shop towels over a vise to prevent ring gear teeth from being nicked after it is free from case assembly. Remove ring gear bolts, leaving four bolts loosely assembled 90 degrees apart. Tap each bolt head alternately with a rawhide or plastic hammer to loosen ring gear from case. Remove case and ring gear from vise. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Page 4912 NOTE: If applicable, use care not to damage exciter ring when removing ring gear. Whenever removing ring gear bolts, discard and replace with new bolts upon assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair Axle Bearing: Service and Repair REMOVAL AND INSTALLATION 1. Remove axle shaft. 2. Insert tool No. T85T-1225-AH, or equivalent, and tool No. T50T-100-A, or equivalent, into axle bore so tangs on tool engage bearing outer race. Remove bearing and seal as an assembly. 3. Install new bearing using tool No. T80T-4000-W, or equivalent, and new seal using tool No. T80T-4000-Y, or equivalent. Pack lips of seal with tool No. C1AZ-19590-B, or equivalent. 4. Reinstall axle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Remove axle shaft bolts. 3. Remove axle shaft and discard gasket. 4. Install a new axle gasket and reinstall axle and bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 4922 Axle Shaft: Service and Repair Ford Integral Carrier Type Axle Full Floating Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Remove axle shaft bolts. 3. Remove axle shaft and discard gasket. 4. Install a new axle gasket and reinstall axle and bolts. Semi Floating Axle REMOVAL AND INSTALLATION 1. Remove axle shaft. 2. Insert tool No. T85T-1225-AH, or equivalent, and tool No. T50T-100-A, or equivalent, into axle bore so tangs on tool engage bearing outer race. Remove bearing and seal as an assembly. 3. Install new bearing using tool No. T80T-4000-W, or equivalent, and new seal using tool No. T80T-4000-Y, or equivalent. Pack lips of seal with tool No. C1AZ-19590-B, or equivalent. 4. Reinstall axle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 AND INSTALLATION 1. Remove axle shaft. 2. Insert tool No. T85T-1225-AH, or equivalent, and tool No. T50T-100-A, or equivalent, into axle bore so tangs on tool engage bearing outer race. Remove bearing and seal as an assembly. 3. Install new bearing using tool No. T80T-4000-W, or equivalent, and new seal using tool No. T80T-4000-Y, or equivalent. Pack lips of seal with tool No. C1AZ-19590-B, or equivalent. 4. Reinstall axle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4930 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4931 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4932 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4933 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4934 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4935 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4936 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4937 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4938 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4939 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4940 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4941 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4942 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4943 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4944 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4945 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4946 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4947 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4948 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4949 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4950 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4951 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4952 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4953 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4954 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4955 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4956 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4957 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4958 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4959 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4960 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4961 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4962 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4963 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4964 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4965 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4966 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4967 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4968 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4969 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4970 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4971 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4972 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4973 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4974 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4975 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4976 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4977 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4978 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4979 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4980 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4981 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4982 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4983 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4984 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4985 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4986 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4987 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4988 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4989 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4990 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4991 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4992 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4993 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4994 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4995 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4996 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4997 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4998 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 4999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5001 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5002 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5003 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5004 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5005 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5006 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5007 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5008 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5009 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5010 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5011 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5012 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5013 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5014 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5015 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5016 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5017 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5018 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5019 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5020 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5021 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5022 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5023 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5024 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 5025 Wheel Bearing: Specifications Wheel Bearing Adjusting Nut [1] ...................................................................................................................................................... 23-34 Nm (17-25 ft lb) Bearing End Play ............................................................................................. .................................................................. 0.006-0.127mm (.00025-.005 in) Hub and Rotor Rotation Torque ................................................................................................................................................. 1.13-2.82 Nm (10-25 in lb) [1] Back nut off approximately one half turn. Tighten nut to 2.03-2.26 Nm (18-20 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Adjustments > Front Wheel Bearing: Adjustments Front 1. Raise the vehicle until the tire clears the floor and install safety stands. 2. Remove the wheel cover or hub cap, if so equipped. 3. Using a suitable tool, remove the grease cap from the hub. Wipe the excess grease from the end of the spindle. Remove the cotter pin and locknut. 4. Loosen the adjusting nut three turns. Attempt to obtain running clearance between the rotor brake surface and the disc pads by rocking the wheel, hub and rotor assembly in and out several times to push the pads away from the rotor. NOTE: Do not pry on the caliper phenolic piston. 5. If running clearance cannot be maintained throughout bearing adjustment in Steps 5 and 6, the caliper must be removed. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 6. Tighten wheel bearing adjusting nut to 23-34 Nm (17-25 ft lb) while rotating the disc brake rotor in the opposite direction. 7. Back nut off approximately one half turn. 8. Tighten nut to 2.03-2.26 Nm (18-20 in lb) while rotating the disc brake rotor. ^ End play should be 0.006-0.127mm (.00025-.005 in). ^ Torque required to rotate the hub should be 1.13-2.82 Nm (10-25 in lb). 9. Install the retainer and new cotter pin bending both ends of cotter pin around retainer. Install grease cap. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Adjustments > Front > Page 5028 Wheel Bearing: Adjustments Rear REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove axle shaft bolts. 5. Using suitable dolly, raise wheel until all weight is removed from wheel bearings. 6. Remove brake drum. 7. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 8. Remove outer bearing, then pull wheel assembly from axle. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. Check for proper seating of bearing cup by trying to insert a 0.0015 in feeler gauge between cups and wheel hub. The gauge should not enter beneath cup. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 15. Install outer wheel bearing and start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 65-75 ft lb Rotate hub occasionally while tightening to set bearings. After torquing to specifications, ratchet back 90°, then torque to 15-20 ft lb. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL AND INSTALLATION 1. Raise and support front of vehicle and remove front wheels. 2. Remove brake caliper and position aside, leaving brake lines attached. CAUTION: 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. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5031 Wheel Bearing: Service and Repair Rear REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove wheel assembly, then remove brake drum. 5. Remove axle shaft bolts. 6. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 7. Install Step Plate Adapter tool No. D80L-630-7 and Puller tool No. D80L-1002-L, or equivalents. Loosen hub until it can be removed. 8. Remove hub, then outer bearing. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Install outer wheel bearing into hub, then slide hub assembly onto axle housing spindle. 15. Start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 55-65 ft lb. Rotate hub occasionally while tightening, to set bearings. After torquing to specifications, ratchet back five clicks (1/8 turn) for new bearing or eight clicks (1/6 turn) for used bearings. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb and tighten axle shaft retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle Wheel Hub: Service and Repair Dana/Spicer Integral Housing Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove axle shaft bolts. 5. Using suitable dolly, raise wheel until all weight is removed from wheel bearings. 6. Remove brake drum. 7. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 8. Remove outer bearing, then pull wheel assembly from axle. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. Check for proper seating of bearing cup by trying to insert a 0.0015 in feeler gauge between cups and wheel hub. The gauge should not enter beneath cup. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 15. Install outer wheel bearing and start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 65-75 ft lb Rotate hub occasionally while tightening to set bearings. After torquing to specifications, ratchet back 90°, then torque to 15-20 ft lb. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle > Page 5036 Wheel Hub: Service and Repair Ford Integral Carrier Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove wheel assembly, then remove brake drum. 5. Remove axle shaft bolts. 6. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 7. Install Step Plate Adapter tool No. D80L-630-7 and Puller tool No. D80L-1002-L, or equivalents. Loosen hub until it can be removed. 8. Remove hub, then outer bearing. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Install outer wheel bearing into hub, then slide hub assembly onto axle housing spindle. 15. Start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 55-65 ft lb Rotate hub occasionally while tightening, to set bearings. After torquing to specifications, ratchet back five clicks (1/8 turn) for new bearing or eight clicks (1/6 turn) for used bearings. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb and tighten axle shaft retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle Wheel Seal: Service and Repair Dana/Spicer Integral Housing Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove axle shaft bolts. 5. Using suitable dolly, raise wheel until all weight is removed from wheel bearings. 6. Remove brake drum. 7. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 8. Remove outer bearing, then pull wheel assembly from axle. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. Check for proper seating of bearing cup by trying to insert a 0.0015 in feeler gauge between cups and wheel hub. The gauge should not enter beneath cup. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 15. Install outer wheel bearing and start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 65-75 ft lb. Rotate hub occasionally while tightening to set bearings. After torquing to specifications, ratchet back 90°, then torque to 15-20 ft lb. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle > Page 5041 Wheel Seal: Service and Repair Ford Integral Carrier Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove wheel assembly, then remove brake drum. 5. Remove axle shaft bolts. 6. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 7. Install Step Plate Adapter tool No. D80L-630-7 and Puller tool No. D80L-1002-L, or equivalents. Loosen hub until it can be removed. 8. Remove hub, then outer bearing. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Install outer wheel bearing into hub, then slide hub assembly onto axle housing spindle. 15. Start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 55-65 ft lb. Rotate hub occasionally while tightening, to set bearings. After torquing to specifications, ratchet back five clicks (1/8 turn) for new bearing or eight clicks (1/6 turn) for used bearings. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb and tighten axle shaft retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Universal Joint - Greasable Design Availability Universal Joint: Technical Service Bulletins Universal Joint - Greasable Design Availability Article No. 97-20-15 09/29/97 ^ DRIVESHAFT - U-JOINT - AVAILABILITY OF GREASEABLE SERVICE PARTS ^ DRIVESHAFT - U-JOINT - IDENTIFICATION OF SERVICE PARTS BY MEASUREMENT ^ DRIVESHAFT - U-JOINTS - IDENTIFICATION OF SERVICE PARTS BY MEASUREMENT LIGHT TRUCK: 1990-96 BRONCO 1990-97 AEROSTAR, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER ISSUE: Available U-joints for driveshaft service are not always identifiable through model application charts. Some customers may request greaseable U-joints as a personal preference. ACTION: Refer to the following Service Information for availability of U-joint with grease fittings. SERVICE INFORMATION TO IDENTIFY U-JOINT BY MEASUREMENT: 1. Remove the old U-joint. 2. Measure U-joint using the following measuring procedure. a. Remove bearing cups. b. Remove excess grease from bottom of bearing cups and trunnions. c. Remove seals from bearing cups and trunnions. d. Reinstall bearing cups on trunnions. e. Measure as follows, permitting a tolerance of 10.005" at Dimension "G" in Figure 1 with Dimension "D" and "E" at 10.003". Outside Snap Ring Style (Figure 1) A) Measure "G" dimension and record. B) Measure "D" dimension and record. C) Measure "E" dimension and record, Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Universal Joint - Greasable Design Availability > Page 5047 3. Identify U-joint part number using reference dimensions in the Light Truck Cross Reference Chart found at the end of this TSB article. TO IDENTIFY GREASEABLE U-JOINT FOR SERVICE: For customers who demand greaseable U-joints due to their specific vehicle duty cycle, refer to Light Truck Cross Reference Chart found at the end of this TSB article. Greaseable U-joints are typically recommended only for vehicles which operate 100% of the time in a high grit environment (e.g., coal mines). NOTE: GREASEABLE U-JOINTS DO NOT CONTAIN END PLAY THRUST WASHERS AND MAY CAUSE NOISE/VIBRATION/HARSHNESS (NVH) CONCERNS ON CERTAIN APPLICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000, 590000, 597997 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > A/T - 4R100 Flexplate Replacement Precaution Flex Plate: Technical Service Bulletins A/T - 4R100 Flexplate Replacement Precaution Article No. 99-23-6 11/15/99 TRANSMISSION - 4R100 - FLEXPLATE REPLACEMENT - VEHICLES WITH 7.3L DIESEL ENGINE - SERVICE TIP FORD: 1994-1997 F SUPER DUTY, F-250 HD, F-350 1994-1999 ECONOLINE 1999 SUPER DUTY F SERIES ISSUE The transmission adapter may cause a misalignment between the flexplate and torque converter causing a pre-load condition between the two components. This concern arises during a transmission flexplate replacement. ACTION Inspect and replace (if necessary) the flexplate reinforcement plate and crankshaft spacer when replacing the flexplate. In addition, replace the engine spacer during this procedure. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS PROCEDURE SHOULD BE USED FOR BROKEN/CRACKED AUTOMATIC TRANSMISSION FLEXPLATES. THIS PROCEDURE IS PARTICULARLY IMPORTANT FOR VEHICLES WHICH HAVE SHOWN REPEAT FAILURES AND/OR LOW MILEAGE FAILURES. 1. Inspect the flywheel reinforcement plate for damage. The plate should be flat and free of any galling. Replace Flywheel Reinforcement Plate (F4TZ-6A366-A) if damaged. 2. Inspect the crankcase spacer for damage. The spacer should be flat and free of any galling. Replace Crankcase Spacer (F81Z-6A366-AA) if damaged. 3. Replace the Engine Spacer (F4TZ-6A369-A). 4. Install the crankshaft spacer and flexplate reinforcement plate (less flexplate) with the flexplate attachment bolts. Tighten to specification. The crankshaft spacer and reinforcement plate should be firmly secured and bolts seated. If the bolts are not seated and/or the parts are still loose, remove the bolts, spacer, and reinforcement plate and bottom tap the crankshaft holes. 5. Reinstall the crankshaft spacer, flexplate, reinforcement plate, and reinstall the flexplate attachment bolts. PART NUMBER PART NAME F4TZ-6A366-A Flywheel Reinforcement Plate F81Z-6A366-AA Crankcase Spacer F4TZ-6A369-A Engine Spacer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 504000, 597997, 601300, 603300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > Page 5052 Flex Plate: Specifications Flywheel Runout 0.2 mm Flywheel to Crankshaft 23-39 ft.lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > Page 5053 Flex Plate: Service and Repair REMOVAL 1. Remove the transmission from the vehicle. 2. Remove the flywheel mounting bolts and the flywheel. 3. Inspect flywheel for cracks, damaged ring gear teeth or any other defects. INSTALLATION 1. Position the flywheel on the crankshaft flange and install retaining bolts. 2. Install transmission into vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel to Crankshaft 89 ft.lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Malfunction Indicator Lamp - A/T > Component Information > Description and Operation Malfunction Indicator Lamp - A/T: Description and Operation Transmission Control Indicator (TCIL) DESCRIPTION Indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Capacity M5OD (Mazda R2) 7.6 pt (US) 5-speed OD S5-42-ZF 6.8 pt (US) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 5067 Fluid - M/T: Fluid Type Specifications Fluid type: Synthetic Mercon Automatic Transmission Fluid Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5072 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5073 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5074 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5075 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5076 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5077 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5078 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5079 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5080 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5081 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5082 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5083 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5084 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5085 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5086 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5087 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5088 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5089 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5090 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5091 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5092 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5093 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5094 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5095 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5096 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5097 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5098 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5099 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5100 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5101 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5102 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5103 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5104 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5105 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5106 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5107 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5108 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5109 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5110 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5111 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5112 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5113 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5114 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5115 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5116 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5117 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5118 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5119 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5120 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5121 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5122 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5123 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5124 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5125 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5126 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5127 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5128 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5129 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5130 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5131 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5132 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5133 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5134 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5135 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5136 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5137 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5138 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5139 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5140 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5141 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5142 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5143 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5144 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5145 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5146 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5147 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5148 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5149 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5150 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5151 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5152 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5153 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5154 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5155 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5156 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5157 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5158 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5159 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5160 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5161 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5162 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5163 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5164 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5165 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5166 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation Power Control Module (PCM). Description The operation of the E4OD automatic transmission is controlled by the PCM. Many input sensors provide information to the PCM, which then controls the actuators which affect transmission operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation Brake Switch - TCC: Description and Operation Brake On/Off (BOO) Switch DESCRIPTION The Brake On/0ff switch tells the powertrain control module when the brakes are applied. The switch is closed when the brakes are applied and open when they are released. FUNCTION Disengages torque converter clutch when brake is applied. RELATED SYMPTOMS Failed on or not connected - Torque converter clutch will not engage at less than 1/3 throttle. Failed off - Torque converter clutch will not disengage when brake is applied. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Description and Operation > Accelerator Pedal (AP) Sensor Throttle Position Sensor/Switch: Description and Operation Accelerator Pedal (AP) Sensor Accelerator Pedal (AP) Sensor DESCRIPTION The Accelerator Pedal (AP) Sensor is mounted on the accelerator pedal and detects the position of the accelerator pedal. OPERATION The accelerator pedal position information is sent as a voltage signal to the PCM. The PCM uses this information to determine shift scheduling and electronic pressure control. FUNCTION If a malfunction occurs in the AP sensor circuit, the PCM will recognize that the AP signal is out of specification. The PCM will then operate the E4OD at a high line pressure to prevent transmission damage. This higher line pressure results in harsh upshifts and engagements. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Description and Operation > Accelerator Pedal (AP) Sensor > Page 5181 Throttle Position Sensor/Switch: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor Description The Throttle Position (TP) sensor is a potentiometer attached to the fuel injection pump and is operated by the throttle lever. Operation The TP sensor is incorporated to provide an electrical signal, which is proportional to the amount of fuel being delivered, as an input to the Powertrain Control Module (PCM). Based on this information, the TP sensor provides the proper shift scheduling and torque capacity. Should a malfunction occur in the TP sensor circuit, the electrical signal sent to the PCM will be recognized as erroneous. When this out-of-specification signal is detected, the PCM will operate the E4OD at a higher line pressure to protect the transmission from potential damage. This high line pressure, results in harsh upshifts and engagements. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power/Economy Mode Switch, A/T Transmission Mode Switch: Description and Operation Power/Economy Mode Switch, A/T Transmission Control Switch (TCS) DESCRIPTION The Transmission Control Switch (TCS) is a momentary contact switch which disables 4th gear operation and enables engine braking when activated. OPERATION When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM). The PCM then energizes the Transmission Control Indicator Lamp (TCIL) and the Coast Clutch Solenoid (CCS), applying the coast clutch to provide engine braking and cancels fourth gear operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power/Economy Mode Switch, A/T > Page 5186 Transmission Mode Switch: Description and Operation Transmission Mode Switch Transmission Control Switch (TCS) DESCRIPTION The Transmission Control Switch (TCS) is a momentary contact switch which disables 4th gear operation and enables engine braking when activated. OPERATION When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM). The PCM then energizes the Transmission Control Indicator Lamp (TCIL) and the Coast Clutch Solenoid (CCS), applying the coast clutch to provide engine braking and cancels fourth gear operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: Customer Interest A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission Transmission Position Switch/Sensor: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission > Page 5202 Transmission Position Switch/Sensor: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only > Page 5205 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission Transmission Position Switch/Sensor: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission > Page 5208 Transmission Position Switch/Sensor: Testing and Inspection With 4R70W Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Output Shaft Speed Sensor <--> [Transmission Speed Sensor, A/T] > Component Information > Locations Output Shaft Speed Sensor: Locations The Output Shaft Speed Sensor is located at the LH rear of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor PURPOSE Used as an input to determine shift schedule and Electronic Pressure Control (EPC) for temperature effects. DESCRIPTION The Transmission Fluid Temperature (TFT) sensor is a temperature-sensitive device called a thermistor it is located in the solenoid body assembly it sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with the transmission fluid temperature. OPERATION The PCM uses the voltage signal to determine whether a cold start shift schedule is necessary. The cold start shift schedule lowers shift speeds to allow for the reduced performance of cold engine operation. The TFT is part of the transmission solenoid assembly and is not replaced separately. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Electronic Pressure Control Solenoid <--> [Pressure Regulating Solenoid, A/T] > Component Information > Description and Operation Electronic Pressure Control Solenoid: Description and Operation DESCRIPTION The Electronic Pressure Control (EPC) Solenoid is a Variable Force Solenoid. The VFS-type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. OPERATION The EPC solenoid supplies Electronic Pressure Control which regulates transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and the line modulator circuits. These two pressures control the clutch application pressures. CAUTION: The electronic pressure control pressure output from the variable force solenoid is NOT adjustable. Any modification to the electronic pressure control solenoid will affect the transmission warranty. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair REMOVAL 1. Remove steering column. 2. Unclip wire terminal from shift interlock actuator. 3. Remove two screws from insert plate and shift interlock actuator. INSTALLATION 1. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Malfunction Indicator Lamp - A/T > Component Information > Description and Operation Malfunction Indicator Lamp - A/T: Description and Operation Transmission Control Indicator (TCIL) DESCRIPTION Indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation Power Control Module (PCM). Description The operation of the E4OD automatic transmission is controlled by the PCM. Many input sensors provide information to the PCM, which then controls the actuators which affect transmission operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation Brake Switch - TCC: Description and Operation Brake On/Off (BOO) Switch DESCRIPTION The Brake On/0ff switch tells the powertrain control module when the brakes are applied. The switch is closed when the brakes are applied and open when they are released. FUNCTION Disengages torque converter clutch when brake is applied. RELATED SYMPTOMS Failed on or not connected - Torque converter clutch will not engage at less than 1/3 throttle. Failed off - Torque converter clutch will not disengage when brake is applied. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Description and Operation > Accelerator Pedal (AP) Sensor Throttle Position Sensor/Switch: Description and Operation Accelerator Pedal (AP) Sensor Accelerator Pedal (AP) Sensor DESCRIPTION The Accelerator Pedal (AP) Sensor is mounted on the accelerator pedal and detects the position of the accelerator pedal. OPERATION The accelerator pedal position information is sent as a voltage signal to the PCM. The PCM uses this information to determine shift scheduling and electronic pressure control. FUNCTION If a malfunction occurs in the AP sensor circuit, the PCM will recognize that the AP signal is out of specification. The PCM will then operate the E4OD at a high line pressure to prevent transmission damage. This higher line pressure results in harsh upshifts and engagements. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Throttle Position Sensor/Switch, A/T > Component Information > Description and Operation > Accelerator Pedal (AP) Sensor > Page 5243 Throttle Position Sensor/Switch: Description and Operation Throttle Position Sensor Throttle Position (TP) Sensor Description The Throttle Position (TP) sensor is a potentiometer attached to the fuel injection pump and is operated by the throttle lever. Operation The TP sensor is incorporated to provide an electrical signal, which is proportional to the amount of fuel being delivered, as an input to the Powertrain Control Module (PCM). Based on this information, the TP sensor provides the proper shift scheduling and torque capacity. Should a malfunction occur in the TP sensor circuit, the electrical signal sent to the PCM will be recognized as erroneous. When this out-of-specification signal is detected, the PCM will operate the E4OD at a higher line pressure to protect the transmission from potential damage. This high line pressure, results in harsh upshifts and engagements. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power/Economy Mode Switch, A/T Transmission Mode Switch: Description and Operation Power/Economy Mode Switch, A/T Transmission Control Switch (TCS) DESCRIPTION The Transmission Control Switch (TCS) is a momentary contact switch which disables 4th gear operation and enables engine braking when activated. OPERATION When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM). The PCM then energizes the Transmission Control Indicator Lamp (TCIL) and the Coast Clutch Solenoid (CCS), applying the coast clutch to provide engine braking and cancels fourth gear operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Power/Economy Mode Switch, A/T > Page 5248 Transmission Mode Switch: Description and Operation Transmission Mode Switch Transmission Control Switch (TCS) DESCRIPTION The Transmission Control Switch (TCS) is a momentary contact switch which disables 4th gear operation and enables engine braking when activated. OPERATION When the switch is pressed, a signal is sent to the Powertrain Control Module (PCM). The PCM then energizes the Transmission Control Indicator Lamp (TCIL) and the Coast Clutch Solenoid (CCS), applying the coast clutch to provide engine braking and cancels fourth gear operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: Customer Interest A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission Transmission Position Switch/Sensor: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > With E4OD Transmission > Page 5264 Transmission Position Switch/Sensor: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > E4OD Transmission Only > Page 5267 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission Transmission Position Switch/Sensor: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Testing and Inspection > With E4OD Transmission > Page 5270 Transmission Position Switch/Sensor: Testing and Inspection With 4R70W Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Output Shaft Speed Sensor <--> [Transmission Speed Sensor, A/T] > Component Information > Locations Output Shaft Speed Sensor: Locations The Output Shaft Speed Sensor is located at the LH rear of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor PURPOSE Used as an input to determine shift schedule and Electronic Pressure Control (EPC) for temperature effects. DESCRIPTION The Transmission Fluid Temperature (TFT) sensor is a temperature-sensitive device called a thermistor it is located in the solenoid body assembly it sends a voltage signal to the Powertrain Control Module (PCM). The voltage signal varies with the transmission fluid temperature. OPERATION The PCM uses the voltage signal to determine whether a cold start shift schedule is necessary. The cold start shift schedule lowers shift speeds to allow for the reduced performance of cold engine operation. The TFT is part of the transmission solenoid assembly and is not replaced separately. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Diode > Component Information > Locations Engine Compartment Fuse Panel Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Diode > Component Information > Locations > Page 5282 ABS Diode: Description and Operation PURPOSE The system diode enables the ABS warning light to illuminate when ignition is ON and the system is disabled by switching the system relay to the default position. OPERATION The system diode is actually a diode/resistor element. The diode/resistor element prevents a false Code 12 from being set when the parking brake is applied. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions ABS Light: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 5287 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 5288 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 5289 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 5290 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 5291 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 5292 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 5293 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 5294 ABS Light: Electrical Diagrams Brake Warning Indicator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Service and Repair ABS Main Relay: Service and Repair REMOVAL and INSTALLATION 1. Open power distribution box. 2. Locate relay in power distribution box. 3. Pull relay from ABS relay socket. 4. For installation, follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration/Deceleration Sensor > Component Information > Description and Operation Acceleration/Deceleration Sensor: Description and Operation PURPOSE This G-Switch is used to determine the vehicle's deceleration rate. OPERATION A component that is unique to the Ford light truck 4-Wheel ABS is the G-Switch, located where the Rear ABS valve used to be. The deceleration rate information, combined with signals from the wheel speed sensors, is used by the ECU to adjust ABS function to different operating conditions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Service and Repair Braking Sensor/Switch: Service and Repair REMOVAL 1. Disconnect wiring harness connector from stoplight switch. 2. Remove self-locking pin and spacer from brake pedal pin. 3. Slide brake booster rod and stoplight switch off brake pedal pin. 4. Remove stoplight switch and bushing from brake booster rod. INSTALLATION 1. Position bushing in stoplight switch. 2. Position stoplight switch on brake booster rod, aligning holes. 3. Slide brake booster rod and stoplight switch onto brake pedal pin. 4. Install spacer and self-locking pin on brake pedal pin. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > RABS Diagnostic Test Connector Diagnostic Connector - ABS: Locations RABS Diagnostic Test Connector C161 (Rear Speed Sensor Test Connector) Full Body View (Part 3 Of 3) The Speed Sensor Test Connector is located below LH side of instrument panel. C238 (For Retrieving/Clearing RABS Trouble Codes) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > RABS Diagnostic Test Connector > Page 5308 Instrument Panel View The Rear Anti-Lock Brakes System (RABS) Test Connector (C238) is a test connector for retrieving/clearing RABS trouble codes, which is located behind RH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > RABS Diagnostic Test Connector > Page 5309 Diagnostic Connector - ABS: Locations 4WABS Systems C161 (Speed Sensor Test Connector) Full Body View (Part 3 Of 3) The Speed Sensor Test Connector is located below LH side of instrument panel. C199 (4WABS Test Connector) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > RABS Diagnostic Test Connector > Page 5310 Full Body View (Part 2 Of 2) The 4 Wheel Anti-Lock Brake System (4WABS) Test Connector is located on 4WABS module. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Anti-Lock Brake System Module: > 98-5A-42 > Mar > 98 > ABS System - 4WABS Lamp On/False ABS Codes In Memory Anti-Lock Brake System Module: Customer Interest ABS System - 4WABS Lamp On/False ABS Codes In Memory Article No. 98-5A-42 03/18/98 ^ BRAKES - 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) - ABS LAMP ILLUMINATED FALSE ABS CODES IN MEMORY - VEHICLES BUILT THROUGH 2/23/96 ^ LAMP - ANTI-LOCK BRAKE SYSTEM (ABS) LAMP ILLUMINATED - FALSE ABS CODES IN MEMORY - VEHICLES BUILT THROUGH 2/23/96 WITH 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) LIGHT TRUCK: 1994-96 ECONOLINE ISSUE: The Anti-lock Brake System (ABS) lamp remains on after the vehicle is started and six (6) ABS codes are stored in memory on some vehicles. This may be due to the programming in the 4WABS module. ACTION: Replace the 4WABS module with a revised module. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm the vehicle has all of the following ABS codes in memory: NOTE: NO MORE, OR LESS, OF THE FOLLOWING CODES MUST BE PRESENT FOR THIS CONCERN. ^ B1342 - ABS Electronic Control Module (ECU) failure ^ C1222 - Wheel speed mismatch ^ C1115 - Power relay output short circuit to battery ^ C1184 - System timeout ^ C1220 - Warning lamp output short circuit to battery ^ C1226 - Brake warning lamp output short circuit to ground 2. If all six (6) codes are present, refer to the 1995 Econoline Service Manual, Pages 06-09B-106 and 06-09B-107 in order to replace the ABS module. Refer to the Application Chart for correct ABS module replacement. PART NUMBER PART NAME F6UZ-2B373-BA ABS Module F6UZ-2B373-CA ABS Module F6UZ-2B373-EA ABS Module OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-7-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Anti-Lock Brake System Module: > 98-5A-42 > Mar > 98 > ABS System - 4WABS Lamp On/False ABS Codes In Memory > Page 5319 OPERATION DESCRIPTION TIME 985A42A Perform Diagnosis And 0.8 Hr. Replace Anti-Lock Brake System Module DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 OASIS CODES: 206000, 301000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Anti-Lock Brake System Module: > 98-5A-42 > Mar > 98 > ABS System - 4WABS Lamp On/False ABS Codes In Memory Anti-Lock Brake System Module: All Technical Service Bulletins ABS System - 4WABS Lamp On/False ABS Codes In Memory Article No. 98-5A-42 03/18/98 ^ BRAKES - 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) - ABS LAMP ILLUMINATED FALSE ABS CODES IN MEMORY - VEHICLES BUILT THROUGH 2/23/96 ^ LAMP - ANTI-LOCK BRAKE SYSTEM (ABS) LAMP ILLUMINATED - FALSE ABS CODES IN MEMORY - VEHICLES BUILT THROUGH 2/23/96 WITH 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) LIGHT TRUCK: 1994-96 ECONOLINE ISSUE: The Anti-lock Brake System (ABS) lamp remains on after the vehicle is started and six (6) ABS codes are stored in memory on some vehicles. This may be due to the programming in the 4WABS module. ACTION: Replace the 4WABS module with a revised module. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm the vehicle has all of the following ABS codes in memory: NOTE: NO MORE, OR LESS, OF THE FOLLOWING CODES MUST BE PRESENT FOR THIS CONCERN. ^ B1342 - ABS Electronic Control Module (ECU) failure ^ C1222 - Wheel speed mismatch ^ C1115 - Power relay output short circuit to battery ^ C1184 - System timeout ^ C1220 - Warning lamp output short circuit to battery ^ C1226 - Brake warning lamp output short circuit to ground 2. If all six (6) codes are present, refer to the 1995 Econoline Service Manual, Pages 06-09B-106 and 06-09B-107 in order to replace the ABS module. Refer to the Application Chart for correct ABS module replacement. PART NUMBER PART NAME F6UZ-2B373-BA ABS Module F6UZ-2B373-CA ABS Module F6UZ-2B373-EA ABS Module OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-7-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Anti-Lock Brake System Module: > 98-5A-42 > Mar > 98 > ABS System - 4WABS Lamp On/False ABS Codes In Memory > Page 5325 OPERATION DESCRIPTION TIME 985A42A Perform Diagnosis And 0.8 Hr. Replace Anti-Lock Brake System Module DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 OASIS CODES: 206000, 301000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 5326 Anti-Lock Brake System Module: Locations Full Body View (Part 2 Of 2) The 4 Wheel Anti-Lock Brakes Module is located on the LH front frame rail. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Diagrams > Four Wheel Antilock Brakes 4 Wheel Anti-Lock Brakes System Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Diagrams > Four Wheel Antilock Brakes > Page 5329 Rear Anti-Lock Brake System Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Description and Operation > Four Wheel Anti-Lock Brake System (4WABS) Anti-Lock Brake System Module: Description and Operation Four Wheel Anti-Lock Brake System (4WABS) PURPOSE The antilock brake electronic control module monitors the brake on/off switch and the system speed sensors to determine when the antilock brake system should be engaged. In addition, the electronic control module provides a speed signal to the Programmable Speedometer/Odometer Module (PSOM). DESCRIPTION It is an on-board diagnostic, non-repairable unit consisting of two microprocessors and necessary circuitry for their operation. These microprocessors are programmed identically. The antilock brake electronic control module monitors system operation during normal driving as well as during antilock braking. OPERATION Under normal driving conditions, the microprocessors produce short test pulses to check the electrical system without any mechanical reaction. The antilock brake electronic control module continuously monitors the speed of each wheel to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the antilock brake electronic control module signals the appropriate solenoid valve in the antilock hydraulic control unit to open or close as well as the pump motor to turn on and recycle brake fluid back to the brake master cylinder. This results in moderate pulsations of the brake pedal and pump noise which may be heard in the passenger compartment. During normal braking, the brake pedal feel will be identical to a standard brake system. Most concerns which occur to the antilock brake system will be stored as a coded number in the Keep-Alive Memory (KAM) of the antilock brake electronic control module. This means that once a code is stored, it will be retained by the antilock brake electronic control module even with the key in the OFF position. The codes can be retrieved by following the on-board diagnostic procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Description and Operation > Four Wheel Anti-Lock Brake System (4WABS) > Page 5332 Anti-Lock Brake System Module: Description and Operation Rear Anti-Lock Brake System (RABS) PURPOSE The Rear Antilock Brake System (RABS) module continuously monitors the rear wheel speed with a sensor mounted on the rear axle for an impending rear wheel lockup condition during braking. The RABS Module will modulate hydraulic pressure to the rear brake cylinders to inhibit rear wheel lockup. The RABS Module has self-test capabilities much like those in other electronic control systems. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) Anti-Lock Brake System Module: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) REMOVAL 1. Disconnect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Locate antilock brake control module on ABS bracket, the bracket is located in the front left hand frame inboard liner just under the driver's seat. Disconnect 40-pin connector from antilock brake control module. 3. Remove screws retaining antilock brake control module to mounting bracket. 4. Gently slide antilock brake control module along bracket and remove antilock brake control module. INSTALLATION 1. Insert antilock brake control module into mounting bracket and install retaining screws (4). Tighten to 7-9 Nm (62-80 lb ft). 2. Install retaining screw and tighten to 7-9 Nm (62-80 lb ft). 3. Connect 40-pin connector and tighten bolt to 6-7 Nm (53-62 lb ft). 4. Connect negative battery cable. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 5335 Anti-Lock Brake System Module: Service and Repair Rear Antilock Brake System (RABS) REMOVAL AND INSTALLATION Anti-Lock Electronic Control Unit 1. Remove the screws/washers that hold the antilock electronic control module to the instrument panel lower brace. Pull the antilock electronic control module off the retainer clip assembly. 2. Disconnect the wiring harness from the antilock electronic control module by depressing the plastic tab on the connector and pulling the connector off. 3. For installation, follow removal steps in reverse order, followed by a system check for proper operation. Tighten screws/washers to 2 Nm (18 lb in) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Locations Hydraulic Control Assembly - Antilock Brakes: Locations Item Part Number Description 1 N807514 Screw 2 5005 Frame 3 W611645-S100 Screw, M10-1.5 x 25.5 4 2234 Front Inlet Tube (Primary) 5 2234 Front Inlet Tube (Secondary) 6 2C286 Hydraulic Control Unit 7 2B112 Intermediate Brake Tube 8 2263 Front Brake Tube (RH) 9 2264 Front Brake Tube (LH) 10 383057-S Union 11 2B373 Anti-Lock Brake Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Connector Views 4 Wheel Anti-Lock Brakes Hydraulic Unit Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Connector Views > Page 5341 Hydraulic Control Assembly - Antilock Brakes: Mechanical Diagrams Item Part Number Description 1 2005 Power Brake Booster 2 -- Outlet, Front Right (Part of 2C286) 3 -- Outlet, Front Left (Part of 2C286) 4 -- Outlet, Rear Axle (Part of 2C286) 5 2C286 Anti-Lock Hydraulic Control Unit 6 -- Pump Motor (Part of 2C286) 7 2140 Brake Master Cylinder Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Brake Pressure Modulator Valve Hydraulic Control Assembly - Antilock Brakes: Description and Operation Brake Pressure Modulator Valve PURPOSE The components of the Rear Anti-Lock Brake System (RABS) valve work together to control pressure to the rear wheel cylinders, inhibiting rear wheel lockup. CONSTRUCTION The RABS valve contains an accumulator, dump solenoid, and an isolation valve. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Brake Pressure Modulator Valve > Page 5344 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Assembly OPERATION Sensing a potential wheel lockup, the Rear Antilock Brake (RABS) module will activate the isolation solenoid within the RABS valve assembly, isolating the rear wheel cylinders from the master cylinder, so that brake pressure cannot increase. If pickup potential is still present with the isolation valve activated, the RABS module will energize the dump solenoid within the RABS valve assembly with rapid pulses to bleed off wheel cylinder fluid into an accumulator built into the RABS valve assembly, reducing rear wheel speed and allowing the rear wheels to spin back up to vehicle speed. The isolation and dump solenoids will continue to be pulsed by the RABS module to keep the rear wheels rotating during braking. When the brake pedal is released, the isolation valve assembly de-energizes and any brake fluid in the accumulator is returned to the master cylinder. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Brake Pressure Modulator Valve > Page 5345 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Pressure Regulating Valve, ABS PURPOSE The brake pressure control valve regulates the hydraulic pressure in the rear brake system. OPERATION When the brake pedal is applied, the full brake fluid pressure passes through the brake pressure control valve to the rear brake system until the valve's split point is reached. Above its split point, the brake pressure control valve begins to reduce the hydraulic pressure to the rear brakes, creating a balanced braking condition between the front and rear wheels to minimize rear wheel lockup during hard braking. CONSTRUCTION The brake pressure control valve is an integral part of the brake master cylinder, located between the rear brake system's inlet and outlet ports in the main valve. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve REMOVAL 1. Disconnect the inlet and outlet brake lines from the RABS valve. 2. Disconnect the wiring harness from the RABS valve. 3. Remove the three screws retaining the RABS valve to the frame rail liner and remove the RABS valve. INSTALLATION 1. Position the RABS valve on the frame side rail. Install the three screws and tighten to 26-32 N-m (19-24 lb-ft). 2. Connect the wiring harness connector to the RABS valve. 3. Connect the brake lines to the RABS valve and tighten as follows: a. 1/2-20 threaded fitting -- 14-23 Nm (10-17 lb ft). b. 7/16-24 threaded fitting -- 14-20 Nm (10-15 lb ft). CAUTION: Do not overtighten the fittings. 4. Perform system brake bleeding procedure. NOTE: It is not necessary to energize the RABS valve electrically to bleed the rear brakes. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 5348 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Assembly REMOVAL 1. Disconnect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect 12-pin connector attaching Hydraulic Control Unit (HCU) to wire harness, and disconnect 2-pin connector attaching pump motor to harness. 3. Remove two tubes from inlet ports and three tubes from outlet ports of HCU. Plug each port to prevent brake fluid from spilling on paint and wiring. NOTE: HCU assembly bracket contains locating hooks on top of the frame. The assembly must be lifted prior to pulling it away from the frame. 4. Remove three nuts retaining HCU assembly and remove assembly from vehicle. INSTALLATION CAUTION: HCU is not interchangeable with other units. Be sure to replace with correct part. 1. Insert HCU assembly into mounting bracket. Install three retaining nuts and tighten to 16-24 Nm (12-18 ft lb). 2. Connect three tubes to outlet ports on side of HCU and two tubes to inlet ports on front of HCU. Tighten tube fittings to 14-24 Nm (10-18 ft-lb). 3. Connect 12-pin connector and 8-pin connector to harness. 4. Connect positive battery cable. 5. Perform system brake bleeding procedures. Check for fluid leaks. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Wheel Speed Sensors Are Not Interchangeable Wheel Speed Sensor: Technical Service Bulletins ABS - Wheel Speed Sensors Are Not Interchangeable Article No. 98-5A-43 03/18/98 BRAKES - ANTI-LOCK BRAKE SYSTEM (ABS) - WHEEL SPEED SENSORS ARE NOT INTERCHANGEABLE LIGHT TRUCK: 1994-95 ECONOLINE ISSUE: The Anti-lock Brake System (ABS) wheel sensors are not interchangeable for 1994-95 Econolines. ACTION: If replacing an ABS wheel sensor, refer to the Econoline Wheel Speed Sensor Application Chart for proper wheel sensor usage. CAUTION: USING THE WRONG WHEEL SENSOR WILL NOT GIVE YOU ANY ERROR CODES, BUT THE WIRES WILL BE MISROUTED. THIS MAY EVENTUALLY CAUSE THE SENSOR WIRE TO CONTACT THE TIRE/WHEEL AND POTENTIALLY RUB THROUGH. PART NUMBER PART NAME F4UZ-2C204-C ABS Wheel Speed Sensor F4UZ-2C204-D ABS Wheel Speed Sensor F6UZ-2C204-AA ABS Wheel Speed Sensor F6UZ-2C204-AB ABS Wheel Speed Sensor OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-13-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensor: Locations Front The front brake antilock sensors are attached to the suspension knuckles, and the front brake antilock sensor indicators are pressed onto the backside of the rotor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front > Page 5355 Wheel Speed Sensor: Locations Rear The Vehicle Speed Sensor (VSS) is located on the axle assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 5356 Wheel Speed Sensor: Description and Operation PURPOSE A variable reluctance sensor and toothed speed indicator ring used to determine wheel speed. OPERATION As the ring teeth pass by the reluctance sensor, a pulsing voltage signal is generated and sent to the antilock brake system control module. Voltage pulses are directly proportional to rotational wheel speed. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Front REMOVAL 1. Raise vehicle on hoist. 2. Remove wheel and tire assembly. Rotor And Speed Sensor Ring 3. Remove caliper, rotor and hub assemblies. Speed Sensor Ring Removal 4. Using a 3-jaw puller, D80L-1013-A or equivalent, remove speed sensor ring from hub. CAUTION: Discard old speed sensor ring after removal. Do not reuse. INSTALLATION 1. Support center of hub so that wheel studs do not rest on work surface. CAUTION: When performing the following step, make sure indicator ring is pressed on straight. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5359 Front Speed Sensor Ring Installation 2. Position new speed sensor ring on hub. Using a cylinder with 98mm (3.9 inch) ID and 106mm (4.2 inch) OD, press the ring on to the hub. The ring must be fully seated against the shoulder in the hub. 3. Install hub, rotor and caliper assemblies. 4. Install wheel and tire assembly. Tighten wheel lugnuts to 115-142 Nm (85-105 ft lb). Rear INSPECTION 1. Remove the sensor. 2. View the speed sensor ring teeth through the sensor hole. Rotate the rear axle and check the speed sensor ring teeth for damage or breakage. Dented or broken teeth could cause the ABS system to function when not required. REMOVAL To service the speed sensor ring, the differential case must be removed from the axle housing, and the speed sensor ring pressed off the case. Upon removal, the speed sensor ring is to be discarded. It is not to be reused. Rear Antilock Brake System (RABS) INSPECTION 1. Remove the sensor. 2. View the speed sensor ring teeth through the sensor hole. Rotate the rear axle and check the speed sensor ring teeth for damage or breakage. Dented or broken teeth could cause the ABS system to function when not required. REMOVAL To service the speed sensor ring, the differential case must be removed from the axle housing, and the speed sensor ring pressed off the case. Upon removal, the speed sensor ring is to be discarded. It is not to be reused. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5360 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Rear Antilock Brake System Rear Speed Sensor REMOVAL 1. At the rear axle housing pull the wiring harness connector from the speed sensor. 2. Remove the speed sensor hold down bolt and remove the speed sensor from the rear axle housing. INSTALLATION 1. Clean the rear axle housing mounting surface. Use care to prevent dirt from entering the rear axle housing. 2. Inspect and clean the magnetized sensor pole piece to make sure that it is free from loose metal particles which could cause erratic system operation. Inspect the speed sensor O-ring for damage and replace if necessary. 3. Lightly lubricate the speed sensor O-ring with motor oil, align the bolt hole, and install. NOTE: Do not apply force to the plastic sensor connector. The sensor flange should slide to the mounting surface. This will make sure the air gap setting is between 0.127-1.143mm (0.005-0.045 in). 4. Install the speed sensor hold-down bolt and tighten to 34-40 Nm (25-29 ft lb). 5. Push the connector on the speed sensor. Front REMOVAL and INSTALLATION 1. From frame rail, disconnect sensor assembly two-pin connector from wiring harness. 2. Separate sensor cable from brake hose clips. 3. Remove sensor out of mating hole. 5. Remove the rotor. 5. For installation, follow removal procedures in reverse order. Tighten retaining bolt to 5-6 Nm (44-53 in lb). Rear REMOVAL Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5361 1. Pull the wiring harness connector from the sensor. 2. Remove the sensor hold down bolt and remove the sensor from the axle housing. INSTALLATION 1. Clean the axle mounting surface. Use care to prevent dirt from entering the axle housing. 2. Inspect and clean the magnetized sensor pole piece to make sure that it is free from loose metal particles which could cause erratic system operation. Replace the sensor O-ring. 3. Lightly lubricate the sensor O-ring with motor oil, align the sensor bolt hole, and install. Do not apply force to the plastic sensor connector. The sensor flange should slide to the mounting surface. This will make sure the air gap setting is between 0.127-1.14mm (0.005-0.045 in). 4. Install the hold down bolt and tighten to 34-40 Nm (25-30 ft lb). 5. Push the electrical connector on the sensor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding NOTE: Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from hydraulic system. 1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to absorb escaping brake fluid. 2. Depress brake pedal slowly forcing air trapped in master cylinder out at fitting. 3. Hold pedal down and tighten fittings, then release brake pedal. NOTE: Releasing brake pedal before fittings are tightened will allow air to enter the master cylinder. 4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm. 5. Bleed brakes as follows: RR, LR, ABS valve, RF, LF 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, 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 the Rear Antilock Brake System (RABS) valve. 7. Bleed the front brakes using same procedure as for rear brakes. 8. Fill master cylinder to 1/4 inch from top of reservoir or to the proper fill line indicated on the fluid reservoir. 9. Centralize pressure differential control valve, if applicable, as follows: a. Turn ignition switch to ACC or ON position. b. Push brake pedal down, allow piston to center itself, turning off warning light. c. Turn ignition switch to the OFF position. 10. Check brake operation and ensure pedal is firm, road test vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5366 Brake Bleeding: Service and Repair Master Cylinder Bleeding 1. Support the master cylinder body in a vise, and fill both fluid reservoirs with heavy duty DOT 3 brake fluid. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake outlet system first. 3. Loosen the plug in the front brake outlet port. Depress the secondary piston slowly to force the air out of the master cylinder. Tighten plug while piston is depressed or air will enter the master cylinder. 4. Repeat this procedure until air ceases to exit at the outlet port. 5. Repeat steps 3 and 4 for the rear brake outlet port with the front brake outlet plugged. 6. Tighten the plugs and try to depress the piston. Depressing the piston should be harder after all air is expelled. 7. Install the plastic cap. 8. Install the master cylinder in the vehicle and bleed the hydraulic system. NOTE: For additional information see Notes, Warnings, and Hints. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5367 Brake Bleeding: Service and Repair Pressure Bleeding Be sure the bleeder tank contains enough of the specified brake fluid to complete the bleeding operation. Charge the tank with approximately 69-206 kPa (10-30 psi). Never exceed 345 kPa (50 psi). Never use brake fluid that has been drained from the hydraulic system. Bleed the longest lines first 1. Clean all dirt from the master cylinder reservoir cap. 2. Remove the master cylinder reservoir cap and fill the master cylinder reservoir with the specified brake fluid. Install the pressure bleeder adapter tool on the master cylinder, and attach the bleeder tank hose to the fitting on the adapter. NOTE: Master cylinder pressure bleeder adapter tools are available from the manufacturers of pressure bleeding equipment. Follow the manufacturer's instructions when installing the adapter. 3. Place a 3/8 inch box wrench on the bleeder fitting on the right rear brake wheel cylinder. Attach a bleeder tube snugly to the bleeder fitting. 4. Open the valve on the bleeder tank and admit pressurized brake fluid to the master cylinder reservoir. 5. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen the bleeder fitting. 6. When air bubbles no longer appear in the fluid at the submerged end of the bleeder tube, close the bleeder fitting and remove the tube. 7. Repeat Steps 3 through 6 at the opposite wheel cylinder. On front brakes, bleed the right front caliper first. 8. When the bleeding operation is completed, close the bleeder tank valve and remove the tank hose from the adapter fitting. 9. Remove the pressure bleeder adapter tool. Fill the master cylinder reservoirs with the specified brake fluid to within 3 mm (1/8 in) from the top of the filler neck. Install the master cylinder cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5368 Brake Bleeding: Service and Repair Priming Brake System When a brake master cylinder (2140) has been installed, or the brake system emptied or partially emptied, fluid may not flow from the wheel cylinder bleeder screws during normal bleeding. It may be necessary to prime the brake master cylinder using the following procedure: 1. Use a tubing wrench to remove the front brake tube (2264) and the brake master cylinder outlet rear tube from the brake master cylinder. 2. Install short brake tubes in the brake master cylinder and position them so that they curve into the brake master cylinder reservoir, and the ends of the tubes are submerged in brake fluid. 3. Fill the brake master cylinder reservoir (2K478) with new Ford High-Performance DOT 3 Brake Fluid C6AZ-19542-AA or -BA or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 4. Have an assistant pump the brakes until clear, bubble-free fluid flows from both brake tubes. 5. Remove the short brake tubes and reinstall the front brake tube and brake master cylinder outlet rear tube (2B253) on the brake master cylinder. 6. Bleed each brake tube at the brake master cylinder using the following procedure: a. Have an assistant pump the brake pedal (2455) 10 times and then hold firm pressure on the brake pedal. b.Loosen the rearmost brake tube fittings with a tubing wrench until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal until the brake tube fitting is tightened again. c. Repeat this operation until clear, bubble-free fluid comes out from around the tube fitting. Refill the brake master cylinder reservoir as necessary. d. Repeat this bleeding operation at the front brake tube fittings. 7. If any of the brake tubes, disc brake calipers (2B120), or rear wheel cylinders have been removed, it may be helpful to prime the system by gravity bleeding. This should be done after the brake master cylinder is primed and bled. To gravity bleed the brake system: a. Fill the brake master cylinder with new Heavy-Duty Brake Fluid C6AZ-19542-AA or -BA or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. b. Loosen both of the wheel cylinder bleeder screws and leave them open until clear brake fluid flows. Be sure to check the brake master cylinder reservoir fluid level often and do not let it run dry. c. Tighten the wheel cylinder bleeder screws (2208) to 7-9 Nm (61-87 in lb). d. One at a time, loosen the caliper bleeder screws. Leave the bleeder screws open until clear fluid flows. Check the fluid level often in the brake master cylinder reservoir and do not let it run dry. e. Tighten the caliper bleeder screws to 17-24 Nm (12-17 ft lb). 8. After the brake system has been primed, bleed the brake system at each wheel (1007). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5369 Brake Bleeding: Service and Repair With ABS SPECIAL TOOLS NEEDED Description Tool Number Antilock Brake Adapter (Bleeder Box) T90P-50-ALA Antilock Brake Adapter T93T-50-ALA (Jumper Cable) EEC-IV Breakout Box T83L-50-EEC-IV CAUTION: Perform this procedure only if the Hydraulic Control Unit (HCU) has been replaced. Follow conventional bleed procedures if the HCU is not being replaced. 1. Perform conventional brake system bleed. 2. Connect Antilock Brake Adapter T90P-50-ALA (bleeder box) and Antilock Brake Adapter T93T-50-ALA (jumper cable). 3. Press down on the brake pedal (2455) and depress the VALVES button on the bleeder box ( brake pedal will fall). 4. Release the VALVES button and release the brake pedal. 5. Repeat above two steps once more. 6. Depress the MOTOR START button and let the pump motor run for one minute. 7. Perform conventional brake system bleed. ANTILOCK BRAKE ADAPTER CONTROLS Item Part Number Description 1 T90P-50-ALA Anti-Lock Brake Adapter (Part of T90P-50-ALA) 2 -- Bleed/Harness Selector (Part of T90P -50-ALA) 3 -- Green "Motor On" Lamp (Part of T90P -50-ALA) 4 -- Red "Motor Off" Lamp (Part of T90P-50-ALA) 5 -- Valve Button (Part of T90P-50-ALA) 6 -- Abort Button (Part of T90P-50-ALA) 7 -- Motor Start Button (Part of T90P-50-ALA) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Adjustments Brake Pedal Assy: Adjustments On brake master cylinder or dash-mounted power brake booster equipped vehicles, the brake systems are designed to permit a full stroke of the master cylinder when the brake pedal is fully depressed. A brake pedal clearance adjustment is not required. To release the brakes, fluid must flow back to the master cylinder through a return port when pedal pressure is released. To be sure the piston moves back far enough to expose the return port, free-travel is built into the pedal linkage on standard booster systems. This prevents the piston from becoming trapped in a partially released position. Pedal-free travel is not always perceptible in dash-mounted booster systems, because the operating clearance for the piston is adjusted at the booster push rod, rather than the pedal linkage. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Adjustments > Page 5373 Brake Pedal Assy: Service and Repair REMOVAL 1. Remove pin and brake master cylinder push rod spacer which connect stoplight switch and power brake booster push rod to brake pedal. 2. Remove stoplight switch, bushing, and brake booster push rod from pedal. 3. Remove nut from long bolt. 4. Slide bolt out far enough to take out brake pedal, brake and clutch pedal bushing, and spring washer. 5. Take brake master cylinder push rod spacer off brake pedal. ITEM PART DESCRIPTION NUMBER 1 2455 Brake Pedal 2 2005 Power Brake Booster 3 382802-S2 Nut 3/8-16 18-34 Nm (13-25 ft lb) 4 56340-S2 Bolt, 3/8-16 x 1 18-34 Nm (13-25 ft lb) 5 2C156 Brake Master Cylinder 6 2A309 Brake Master Cylinder Push Rod Bushing 7 2B129 Brake Master Cylinder Push Rod Spacer 8 380699-S100 Self-Locking Pin 9 13480 Stoplight Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Adjustments > Page 5374 10 Top Cowl (Part of 2455) INSTALLATION 1. Install brake master cylinder push rod spacer on brake pedal. 2. Slide spring washer and brake and clutch pedal bushings onto brake pedal and hold. 3. Position brake pedal and assembled parts up into support bracket. 4. Push bolt through bracket and brake pedal. 5. Install nut on long bolt. 6. Install stoplight switch, brake and clutch pedal bushing, and brake booster push rod onto pin on brake pedal. 7. Install spacer and pin retaining stoplight switch on brake pedal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation Service Brakes The brake warning light in the instrument cluster is used to warn of system malfunctions. The red warning light for the brakes can indicate three conditions: The parking brake is not fully released. - The brake fluid level is low in the master cylinder reservoir. - The vacuum pressure is low on diesel engine vehicles. Diesel vehicles use a low vacuum indicator switch. The low vacuum indicator switch is located on the left side of the engine compartment near the vacuum pump. The low vacuum indicator switch will turn on the brake warning lamp when a low vacuum situation occurs. Rear Anti-Lock Brakes The yellow anti-lock brake indicator lights up for approximately two seconds when the key is first moved to RUN or START for circuit proveout. The indicator also lights up when the RABS module detects a malfunction in the system. The self-test feature contains codes that indicate the area of the malfunction. When a malfunction is detected, the RABS control module shuts down the system and the yellow anti-lock warning indicator comes on. This permits normal braking. A code can be retrieved by momentarily grounding the diagnostic pigtail (black with orange stripe wire) after it is disconnected from KAM (keep-alive power red wire) and counting the flashes of the yellow ABS lamp. To make sure the diagnostic trouble code (DTC) is not lost from memory, the key must be left in the RUN position before the diagnostic lead is disconnected from KAM power. If more than one diagnostic trouble code exists, only the first code stored will be displayed. Additional codes will be output only after the first fault is corrected. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Slide Bolts 22-26 ft.lb Caliper Anchor Mounting Bolts 85-100 ft.lb Brake Hose Block Bolt 10-15 ft.lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 5382 Brake Caliper: Diagrams Caliper Exploded View NOTE: Both caliper pistons are located on the inboard side and function exactly as a single piston unit. Dual pistons are used to produce higher braking forces (due to the greater total piston surface area). They also result in more uniform application of the larger brake pads used on these trucks. ITEM PART NUMBER DESCRIPTION 1. 2196 Wheel Cylinder Piston. 2. - Piston Boot (Part of 2B120). 3. - Piston Seal (Part of 2B120). 4. 2B120 Front Disc Brake Caliper. 5. 2B164 Disc Brake Pad Anti-Rattle Clip. 6. 2001 Brake Shoe and Lining. 7. - Bleeder Screw (Part of 2B120). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 5383 Brake Caliper: Testing and Inspection NOTE: When raising the vehicle make sure that the hoist lift points do not rest on the caliper pins. 1. Raise vehicle on hoist. 2. Remove the wheel and tire from the front disc brake hub and rotor (1102). 3. Visually check the disc brake caliper (2B120). If the disc brake caliper housing is leaking, it should be replaced. If a caliper piston (2196) is leaking, the caliper disc brake caliper must be disassembled and new caliper piston installed. If a caliper piston is seized in the bore, a new disc brake caliper housing is required. CAUTION: Do not pry on plastic caliper piston with a screwdriver or other tools, as this will cause chipping. 4. If a disc brake caliper caliper piston is removed for any reason, the piston seal must be replaced. Exercise care not to damage plastic caliper piston by protecting it from contact with any metal or sharp objects. 5. Clean all metal parts with isopropyl alcohol. Then, clean out and dry the grooves and passageways with compressed air. Make sure that caliper bore and component parts are thoroughly clean and dry prior to assembly. 6. Check the cylinder bore and caliper piston for excessive scoring or corrosion. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front DISASSEMBLY Dual Piston Brake Caliper 1. Drain the fluid from the cylinders. 2. Secure the caliper assembly in a vise. 3. Place a block of wood between the caliper bridge and the cylinders, and apply low pressure air to the brake hose inlet. The pistons will be forced out to the wood block. Removing Caliper Piston 4. Remove the wood block, and remove the pistons. 5. Remove and discard the piston seals and boots. 6. If the caliper assembly is leaking, replace the piston assemblies. If the cylinder bores are scored, corroded or excessively worn, replace the caliper. Do not hone the cylinder bores. Piston assemblies are not available for oversize bores. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5386 CLEANING and INSPECTION Clean all metal parts with isopropyl alcohol. Clean out and dry the grooves and passageways with compressed air. Make sure that caliper bore and component parts are thoroughly clean. Use a wire brush to remove any rust or corrosion from the machined surfaces of the caliper housing. NOTE: Do not use a wire brush in the cylinder bore. Check the cylinder bore and piston for damage or excessive wear. Replace the piston if it is pitted, scored or worn. Do not replace phenolic pistons for cosmetic surface irregularities or small chips between the piston groove and pad face. Use a wire brush to clean corrosion from the boot groove and the machined surfaces of the spindle assembly. Replace the anti-rattle clip, piston seal and dust boot with new components. ASSEMBLY NOTE: Never re-use piston seals and dust boots. Install a new set each time the caliper is assembled. 1. Lubricate new piston seals with clean brake fluid. Install them in the seal grooves in the cylinder bores. 2. Apply a film of clean brake fluid to the cylinder bores. 3. Lubricate retaining lips of the dust boots with clean brake fluid and install them in the boot retaining grooves in the cylinder bores. 4. Apply a film of clean brake fluid to the pistons. 5. Insert the pistons into the dust boots and start them into the cylinders by hand until they are beyond the piston seals. Be careful not to damage or dislodge the piston seal. 6. Place a wood block over one piston and press the piston into the cylinder being careful not to cock the piston in the cylinder. Install the second piston in the same manner. Make certain that boots are correctly seated. 7. Install the pad and lining assemblies and anti-rattle spring in the caliper assembly. Place the caliper assembly on the support and install the caliper pins. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5387 Brake Caliper: Service and Repair Inspection For additional information see Installation Notes. See: Fundamentals and Basics 1. Install caliper slide pins through disc brake caliper and front wheel spindle. Tighten bolts to 30-36 Nm (22-26 lb ft). 2. If front brake hose was removed, replace both washers (each side of inlet block). Connect the front brake hose. Tighten inlet block bolt to 14-20 Nm (10-15 lb ft). Perform brake bleeding procedures. 3. Install wheel and tire assembly. Remove the safety stands and lower the vehicle. 4. If the brakes were not bled, and disc brake caliper was not removed check the fluid level in the brake master cylinder reservoir and fill if required. 5. Pump the brakes several times to make sure you get a firm brake pedal. 6. Operate the vehicle to check brake operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5388 Brake Caliper: Service and Repair Removal For additional information see Removal Notes. See: Fundamentals and Basics 1. To avoid fluid overflow when the caliper pistons are pressed into the caliper cylinder bores, remove part of the brake fluid out of the brake master cylinder reservoir. Discard the removed fluid. 2. Raise the vehicle on a hoist and install safety stands. Remove the wheel and tire assembly. NOTE: When raising the vehicle make sure that the hoist lift points do not rest on the caliper pins. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5389 Bottoming Caliper Pistons 3. Place an appropriate size C-clamp on the disc brake caliper with end of clamp against caliper and end of screw against outer pad. Tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the C-clamp. NOTE: Do not use a screwdriver or similar tool to pry the caliper piston away from the front disc brake hub and rotor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5390 Removing Caliper Assembly 4. Remove both caliper slide pins. Examine the slide pins to assure that they are not damaged. Replace if necessary. 5. Remove the disc brake caliper assembly. Remove brake pad linings. CAUTION: Do not let the disc brake caliper hang by the brake hose. The brake hose could become stretched or twisted, which can cause the front brake hose to leak and rupture. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5391 Removing Caliper Assembly 6. If the disc brake caliper is to be removed for repair or replacement, disconnect the front brake hose from the disc brake caliper. Plug the end of the front brake hose to prevent fluid loss and the entry of air into the system. If the disc brake caliper is not to be removed, secure it to the frame of the vehicle to avoid damage to the front brake hose. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes Brake Caliper: Fundamentals and Basics Removal Notes When Removing the Caliper, Remember... - Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir is only 1/3 full. - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining thickness between wheels on the same axle will result in a strong steering pull when the brakes are applied. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. - When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is forced back into the caliper, these deposits will be forced back through the brake lines and into the master-cylinder. - When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a glass or plastic jar to catch the expelled fluid. - Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses can be damaged easily by this practice. These hoses are double walled, damage to the interior pressure hose will not be visible. - Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not attempt to insert the piston back into the caliper. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 5394 Brake Caliper: Fundamentals and Basics Installation Notes WHEN INSTALLING CALIPERS AND PADS, REMEMBER... - Clean and lubricate caliper slide joint/pins with high temperature silicone grease: Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted movement of the caliper slide assemblies to release the brakes. If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon the release of the brake pedal. This will result in overheated brakes and premature brake wear. Disc Brake Mechanical Force Diagram NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel forces the inner pad against the rotor, then further travel forces the movable part of the caliper to pull the outer pad against the rotor. High temperature silicone lubricant must be used. Low temperature grease can melt and contaminate the pads and rotors, or can bake into a very hard substance which binds the slides. Petroleum based grease can cause the slide boots to soften and swell. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. Anti-squeal Coating - Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an insulator to dampen high frequency vibrations that are generated during normal braking. These compounds are highly effective in preventing brake squeal. - Many professional repair shops recommend always rebuilding or replacing the calipers when replacing the brake linings, because: When the pistons are forced back into the calipers, the piston seals are dragged across any corrosion or abrasives that may be deposited on the inside of the caliper. Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston is gradually withdrawn from the caliper. This results in the piston seals again being dragged across the layer of corrosion and deposits. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 5395 Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking. - Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck bleeder screw is much easier with the caliper removed from the vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Testing and Inspection Brake Pad: Testing and Inspection 1. Inspect brake shoes and brake shoe and lining (2001) for wear. If the lining is worn to within 3mm (1/8 inch) of the shoe, replace all (four) shoe and lining assemblies (complete axle set) on front wheels as required. 2. Do not attempt to clean or restore any oil or grease-soaked brake shoes and linings. When contaminated brake shoes and linings are found, they must be replaced in complete axle sets. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Installation Brake Pad: Service and Repair Installation For additional information see Installation Notes. See: Brake Caliper/Fundamentals and Basics 1. Install caliper slide pins through disc brake caliper and front wheel spindle. Tighten bolts to 30-36 Nm (22-26 lb ft). 2. If front brake hose was removed, replace both washers (each side of inlet block). Connect the front brake hose. Tighten inlet block bolt to 14-20 Nm (10-15 lb ft). Perform brake bleeding procedures. 3. Install wheel and tire assembly. Remove the safety stands and lower the vehicle. 4. If the brakes were not bled, and disc brake caliper was not removed check the fluid level in the brake master cylinder reservoir and fill if required. 5. Pump the brakes several times to make sure you get a firm brake pedal. 6. Operate the vehicle to check brake operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Installation > Page 5401 Brake Pad: Service and Repair Removal For additional information see Removal Notes. See: Brake Caliper/Fundamentals and Basics 1. To avoid fluid overflow when the caliper pistons are pressed into the caliper cylinder bores, remove part of the brake fluid out of the brake master cylinder reservoir. Discard the removed fluid. 2. Raise the vehicle on a hoist and install safety stands. Remove the wheel and tire assembly. NOTE: When raising the vehicle make sure that the hoist lift points do not rest on the caliper pins. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Installation > Page 5402 Bottoming Caliper Pistons 3. Place an appropriate size C-clamp on the disc brake caliper with end of clamp against caliper and end of screw against outer pad. Tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the C-clamp. NOTE: Do not use a screwdriver or similar tool to pry the caliper piston away from the front disc brake hub and rotor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Installation > Page 5403 Removing Caliper Assembly 4. Remove both caliper slide pins. Examine the slide pins to assure that they are not damaged. Replace if necessary. 5. Remove the disc brake caliper assembly. Remove brake pad linings. CAUTION: Do not let the disc brake caliper hang by the brake hose. The brake hose could become stretched or twisted, which can cause the front brake hose to leak and rupture. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Installation > Page 5404 Removing Caliper Assembly 6. If the disc brake caliper is to be removed for repair or replacement, disconnect the front brake hose from the disc brake caliper. Plug the end of the front brake hose to prevent fluid loss and the entry of air into the system. If the disc brake caliper is not to be removed, secure it to the frame of the vehicle to avoid damage to the front brake hose. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment Technical Service Bulletin # 98-5A-5 Date: 980318 Hub-Mount Brake Rotor Machining Equipment Article No. 98-5A-5 03/18/98 ^ BRAKES - AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT ^ BRAKE ROTOR MACHINING - AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1993-98 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE: Hub-mount brake rotor machining equipment from Rotunda is now approved for warranty and service use. Brake roughness consists of one or more of the following symptoms while braking: ^ Steering wheel vibration/nibble ^ vibration ^ Brake pedal pulsation Brake roughness is caused by: ^ Uneven rotor wear known as Disc Thickness Variation (DTV). DTV is caused by excessive Lateral Run-Out (LRO) or overtorqued wheel lug nuts ^ Non-uniform lining transfer ACTION: Use Rotunda Hub-Mount Lathe / Pro-Cut (201-00002) to service vehicles with brake roughness. The hub-mount lathe removes DTV, lining transfer, and on-vehicle rotor LRO. The hub-mount lathe has the following advantages over caliper-mount lathes: ^ Improved rotor LRO and "dishing" tolerances ^ Ability to machine rear rotors on live axles, except for trucks with dual rear wheels ^ Easier set-up Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 5409 Refer to the Service Procedure for details. PART NUMBER PART NAME F6AZ-9L494-AA High Temperature Nickel Anti-Seize Lubricant OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-4-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 702300, 703000, 703400 Service Procedure 1. Verify concern. 2. Pre-checks to include: ^ Check OASIS and TSBs for vehicle-specific brake/vibration concerns ^ Visually inspect suspension bushings/ball joints ^ Visually inspect tire conditions and pressure ^ Check wheel bearing end-play 3. Remove wheel/tire. 4. Remove caliper. 5. For vehicles with two-piece hub/rotor: a. Mark rotor and wheel stud for proper indexing during reassembly. b. Remove rotor. NOTE: THE ROTOR MUST HAVE SUFFICIENT THICKNESS AFTER MACHINING TO BE OVER THE MINIMUM THICKNESS SPECIFICATION C 6. Measure rotor thickness and record measurement. Replace rotor if below the minimum thickness specification cast in the rotor. CAUTION: DO NOT USE ABRASIVE SANDING DISC SINCE IT WILL REMOVE METAL FROM MOUNTING SURFACES AND ADVERSELY AFFECT 7. Remove corrosion from wheel mounting surface, both rotor mounting surfaces, and hub mounting surface. A die grinder with a Scotchbrite(R) surfa 8. For vehicles with two-piece hub/rotor, reinstall rotor onto hub, aligning with marks from Step 5a. NOTE: READ THE ENTIRE OPERATING MANUAL AND VIEW THE VIDEO SHIPPED WITH THE LATHE BEFORE INSTALLING, OPERATING, OR SERVICING THE LATHE. 9. Machine rotors using the Rotunda Hub-Mount Brake Lathe / Pro-Cut (201-00002). a. Install hub adapter and silencer belt (where applicable). b. Install cutting lathe. NOTE: TOTAL INDICATED READING (TIR) TARGET IS 0.000 mm, MAXIMUM IS O.O6 mm (0.003"). c. Adjust lathe oscillation using a dial indicator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 5410 NOTE: DEPTH OF CUT SHOULD BE BETWEEN 0.10 AND O.2O mm (0.004 AND 0.008"). LIGHTER CUTS WILL CAUSE THE BIT TO HEAT UP A d. Center cutting head, adjust cutting bits, install chip deflector. e. Machine rotor. f. Measure and record rotor thickness. NOTE: TARGET LRO IS 0.000 mm, MAXIMUM IS O.05 mm (0.002"). g. Install dial indicator, measure and record rotor LRO. Remove dial indicator. h. Remove lathe and silencer belt. 10. Remove metal shavings. 11. Remove the adapter. 12. For vehicles with two-piece hub/rotors: a. Remove rotor from hub. b. Remove metal shavings from hub and rotor mounting surfaces and from ABS sensors. c. Apply High Temperature Nickel Anti-Seize Lubricant (F6AZ-9L494-AA) to hub mounting surface to prevent future corrosion. d. Match marks on rotor and hub and assemble rotor to hub. 13. Install pads and calipers. NOTE: USING AN IMPACT TOOL WITHOUT AN ACCUTORO(R) SOCKET WILL LEAD TO UNEVENLY TORQUED LUG NUTS. THIS CAUSES ROTOR 14. Install wheels using impact guns equipped with Rotunda AccuTorq(R) sockets. Use a torque wrench on locking lug nuts. 15. Check brake operation before returning to customer. Support Telephone Numbers 1. Lathe Administration Support: (800) 768-8632 2. Pro-Cut Technical Support: (800) 543-6618 Reference list for Pro-Cut car labor operations: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 5411 ^ A = Aspire ^ B = Escort/Tracer ^ C = Probe ^ D = Contour/Mystique ^ E = Mustang ^ F = Taurus/Sable ^ G = Thunderbird/Cougar ^ H = Crown Victoria/Grand Marquis ^ I = Continental ^ J = Mark VIII ^ K = Town Car ^ L = Festiva ^ M = Tempo/Topaz Reference list for Pro-Cut light truck labor operations: ^ AA = Villager ^ AB = Windstar ^ AC = Aerostar 4X2 ^ AD = Aerostar 4X4 ^ AE = Ranger 4X2 ^ AF = Ranger 4X4 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 5412 ^ AG = Explorer/Mountaineer 4X2 ^ AH = Explorer/Mountaineer 4X4 ^ AI = Econoline ^ AJ = F-250 HD/F-350 4X2 ^ AK = F-250 HD/F-350 4X4 ^ AL = F-Super Duty ^ AM = F-150/F-250 LD 4X2 ^ AN = F-150/F-250 LD 4X4 And Bronco ^ AO = Expedition/Navigator 4X2 ^ AP = Expedition/Navigator 4X4 ^ AQ = Super Duty F Series Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 5413 Brake Rotor/Disc: Technical Service Bulletins Brakes - Elimination Of Sanding Rotors And Drums Article No. 98-5A-11 03/18/98 BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-97 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Repeat brake repairs have been performed due to sanding of brake rotors and drums. The sanding of rotors and drums may have been done in reference to a Service Manual or TSB article which prescribes sanding as a repair, however, sanding is neither an effective nor lasting repair for customer complaints of brake roughness or noise. ACTION: Machine brake rotors and drums instead of sanding to help reduce brake roughness caused by one of the following conditions: ^ Rotor thickness variation and lateral runout ^ Lining or foreign material build-up ^ Drum out-of-round NOTE: DO NOT MACHINE OR SAND ROTORS/DRUMS TO REDUCE OCCASIONAL BRAKE NOISE. IT IS NEITHER AN EFFECTIVE OR LASTING REPAIR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5414 Brake Rotor/Disc: Specifications Minimum Allowable Thickness 1.10 in Maximum Variation (Parallelism) 0.013 in Lateral Runout 0.003 in Rotor Surface Finish 15-80 micro-in Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5415 Brake Rotor/Disc: Description and Operation PURPOSE A front disc brake rotor shield (2K004), bolted to the front wheel spindle (3105), protects the bearings and inboard surface of the front disc brake hub and rotor (1102) from road splash. The wheel protects the outboard surface of the front disc brake hub and rotor and disc brake caliper (2B120). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Rotor/Disc: Initial Inspection and Diagnostic Overview NOTE: Grease or any other foreign material must be kept off the brake shoe and lining (2001) surfaces of the rotor and external surfaces of the front disc brake hub and rotor (1102) during service operations. In handling the front disc brake hub and rotor and disc brake caliper (2B120) assemblies, avoid deformation of the front disc brake hub and rotor and nicking or scratching of brake shoes and linings. PURPOSE In the manufacturing of the brake rotor all the tolerances regarding surface finish, parallelism, and lateral runout are held very closely. The maintenance of these tolerances provide the surface necessary to prevent brake roughness. Light scoring of the rotor surface not in excess of 0.38 mm (0.015-inch) in depth is normal. This condition does not affect the brake operation. Some discoloration or wear of the disc surface is normal and does not require re-surfacing when linings are replaced. SPECIFICATIONS - See: Specifications LATERAL RUNOUT Lateral runout is the movement of the rotor from side to side as it rotates on the spindle. This could also be referred to as "rotor wobble". This movement causes the brake pad and piston to be knocked back into it's bore. This results in additional pedal travel and a vibration during braking. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5418 Checking Lateral Runout 1. Tighten the wheel bearings to eliminate all freeplay. 2. Attach a dial indicator to a solid non-rotating portion of the hub assembly or suspension. - The point of the styles must contact the rotor face about 25 mm (1-inch) from the rotor edge. 3. Move the rotor one complete rotation and observe the dial indicator. 4. Rotate the bezel on the dial indicator such that "0" is at the low deflection point. 5. Again rotate the rotor at least one complete turn and observe the needle deflection. Total needle deflection will equal lateral runout. 6. Readjust the wheel bearings. MINIMUM THICKNESS The thickness of a rotor is important for two reasons: 1. Rotors which are too thin are not able to properly absorb and release heat during heavy braking. This results in reduced braking capacity and brake fade. 2. Rotors worn below minimum thickness in combination with worn pads/linings can result in the caliper piston extending too far becoming cocked or jammed. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5419 Rotor thickness should be measured at the thinnest point on the rotor. Any rotor which is worn below its minimum thickness should be replaced. For accurate measurements, it is best to remove the caliper to allow for complete access to the inboard side of the rotor. For more information on how to use a disc brake micrometer see Fundamentals and Basics. PARALLELISM Parallelism is the measurement of the thickness of the rotor at 12 or more points around the circumference of the rotor. All measurements must be made at the same distance in from the edge of the rotor. Lack Of Parallelism Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5420 Lack Of Parallelism MACHINING Since accurate control of the rotor tolerances is necessary for proper performance of the disc brakes, machining of the rotor should be done only with precision equipment. All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. Do not use a brake rotor that will not meet the specifications, after refinishing. Replace with a new brake rotor. NOTE: 1 inch = 25.4mm, so if your micrometer measures in inches and the specified thickness on the disc is in millimeters, convert millimeters to inches by dividing the specified number of millimeters by 25.4. Example: Specification on disc is 17.8 mm. Dividing 17.8mm by 25.4mm/in = 17.8/25.4 = 0.70 inches. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5421 Brake Rotor/Disc: Component Tests and General Diagnostics WARNING: Never install a front disc brake rotor that has been turned to minimum wear or discard thickness. Measure the thickness of the front disc brake rotor to determine if it is within specifications. Front disc brake rotor minimum (discard) thickness is stamped on the front disc brake rotor. Front disc brake rotors have a minimum thickness dimension (minimum wear thickness or discard thickness). This is not the refinishing dimension. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Installation Brake Rotor/Disc: Service and Repair Installation Wheel bearing lubricant is a lithium-base grease. Sodium-base grease is not compatible with lithium-base grease and should not be intermixed. Therefore, do not lubricate front and/or rear wheel bearings without first identifying the type of original wheel bearing lubricant. Usage of incompatible bearing lubricants may result in premature lubricant breakdown. 1. If a new hub and rotor will be installed, remove the protective coating, any dirt or grease deposits with brake parts cleaner or degreaser. 2. Pack the inside of the hub with lithium-base grease or equivalent. Fill the hub until the grease is flush with the inside diameters of both bearing cups. Pack the bearing cones and rollers with wheel bearing grease. Use a bearing packer for this operation. If a packer is not available, work as much lubricant as possible between the rollers and cages. Lubricate the cone surfaces with grease. Installing Grease Seal (Typical) 3. Place the inner bearing cone and roller in the inner cup and install the new grease seal. Be sure that the seal is fully seated. 4. Install the hub and rotor on the wheel spindle. Keep the hub centered on the spindle to prevent damage to the grease retainer or the spindle threads. 5. Install the outer bearing cone and roller and the flat washer on the spindle, then install the adjusting nut, and adjust the wheel bearing. 6. Install the retainer, new cotter pin, and grease cap. 7. Install the caliper. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Installation > Page 5424 Brake Rotor/Disc: Service and Repair Refinishing Each time the brakes are serviced, the disc brake rotor should be checked for scoring, runout, parallelism and thickness. ROTOR MACHINING Do not machine, cut or true up new front disc brake hub and rotors prior to installation on vehicle. Making a light cut on a new front disc brake hub and rotor may cause excessive runout and result in brake shudder several thousand miles later. It is best to clean oil film off new front disc brake hub and rotor with Brake Cleaner or equivalent install it on vehicle. Never use a brake lathe that cuts only one face of the front disc brake hub and rotor at a time. It must be a simultaneous straddle cut. All front disc brake hub and rotor refinishing must adhere to the rule that equal amounts of front disc brake hub and rotor stock are removed from each braking surface each time a front disc brake hub and rotor is refinished. On-vehicle brake lathes, machine the front disc brake hub and rotor while it is on the hub and is turning on the same axis as the hub. This procedure reduces front disc brake hub and rotor lateral runout to near zero by cutting the front disc brake hub and rotor perpendicular to the axis of the hub, therefore cancelling the affect of stacked tolerance of the front disc brake hub and rotor and front wheel spindle. Follow the on-vehicle brake lathe manufacturer's instructions on machining procedures. A bench-mounted disc brake lathe machines the disc brake hub and rotor to the axis of the lathe arbor and will not reduce total lateral runout associated with stacked tolerances of the front disc brake hub and rotor and front wheel spindle. Follow manufacturer's instructions on machining procedures. With both types of brake lathes, set cutting tool to just contact the high spots on the front disc brake hub and rotor then adjust cutting tool to the minimum depth required to clean up the front disc brake hub and rotor face. The total material removed (combination of both sides) must not exceed the minimum discard thickness that is marked on the inside of the front disc brake hub and rotor. To improve initial brake pedal feel and surface finish on a machined front disc brake hub and rotor, lightly sand rotor surface with 120 grit paper prior to road testing. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Installation > Page 5425 Brake Rotor/Disc: Service and Repair Removal 1. Raise the vehicle until the tire clears the floor and remove the wheel and tire assembly. 2. Remove the brake caliper and secure to the underbody to prevent damage to the brake hose. It is not necessary to disconnect the hose from the caliper. Do not let the caliper hang with its weight on the brake hose or the hose may become stretched, twisted or ruptured. 3. Remove the grease cap, cotter pin, retainer adjusting nut and washer. 4. Remove the outer bearing cone and roller. 5. Pull the hub and rotor off the spindle and remove and discard the grease seal. 6. Remove the inner bearing cone and roller from the hub. Remove all traces of old lubricant from bearings, hub and axle spindle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Installation > Page 5426 Brake Rotor/Disc: Service and Repair Runout Check Rotor Run-out Check NOTE: Whenever brake front disc brake hub and rotor has been separated from hub face, clean any rust or foreign material from mating surface on hub face and front disc brake hub and rotor. Failure to do this may result in increased lateral runout of the front disc brake hub and rotor and brake pulsation. Install front disc brake hub and rotors on hubs and hold in place by using inverted wheel lug nuts and washers to seat front disc brake hub and rotors to hubs. Tighten wheel lug nuts to 115-142 Nm (85-105 ft lb). Using a dial indicator D78P-4201-B, or equivalent, measure front disc brake hub and rotor lateral runout as shown. The dial indicator should be centered on brake surface. Rotate front disc brake hub and rotor while measuring runout. If runout is greater than 0.08mm (0.003 inch), front disc brake hub and rotor must be repositioned (indexing) on hub to obtain the lowest possible runout. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Full-Floating Rear Axle Backing Plate: Service and Repair Full-Floating Rear Axle REMOVAL 1. Remove the wheel and brake drum. Disconnect the rear brake tube from the rear wheel cylinder and submerge the end of the rear brake tube in a can containing a small amount of brake fluid to prevent air from entering the system. 2. Remove the rear brake shoes and linings, brake hardware and rear wheel cylinder. 3. Disconnect the parking brake lever from the cable. 4. Remove the bolts holding the axle to the hub, slide the axle shaft out of the housing. 5. Remove the hub from the axle housing. 6. Remove the brake backing plate bolts, then the backing plate. INSTALLATION 1. Install the backing plate and mounting bolts to the axle housing assembly. 2. Install the rear wheel cylinder and rear brake shoes and linings. Connect the parking brake cable to the lever. 3. Install the hub and axle assemblies. 4. Connect the rear brake tube to the rear wheel cylinder and install the brake drum and wheel. Adjust the rear brake shoes and linings. See: Adjustments Perform brake bleeding procedure. 5. Tighten the wheels to 190 Nm (140 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Full-Floating Rear Axle > Page 5432 Backing Plate: Service and Repair Semi-Floating Rear Axle REMOVAL 1. Remove the wheel and brake drum. Disconnect the rear brake tube from the rear wheel cylinder and submerge the end of the rear brake tube in a can containing a small amount of brake fluid to prevent air from entering the system. 2. Remove the rear brake shoes and linings and rear wheel cylinder. 3. Disconnect the parking brake lever from the cable. 4. Remove the C-clip in the differential case which holds the axle shaft in place. After the C-clip has been removed, slide the axle shaft out of the housing. CAUTION: Care must be taken to not damage the axle seal when removing the axle. 5. Remove the brake backing plate bolts then the brake backing plate. INSTALLATION 1. Position the brake backing plate on the retaining bolts in the axle housing flange and tighten bolts to 68-95 Nm (50-70 ft lb). 2. Install the rear axle. 7. Install the rear wheel cylinder and rear brake shoes and linings. On rear brakes, connect the parking brake cable to the lever. 8. Connect the rear brake tube to the rear wheel cylinder and install the brake drum and wheel. Adjust the rear brake shoes and linings and perform brake bleeding procedure. 9. Tighten the wheels to 190 Nm (140 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Elimination Of Sanding Rotors And Drums Brake Drum: Technical Service Bulletins Brakes - Elimination Of Sanding Rotors And Drums Article No. 98-5A-11 03/18/98 BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-97 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Repeat brake repairs have been performed due to sanding of brake rotors and drums. The sanding of rotors and drums may have been done in reference to a Service Manual or TSB article which prescribes sanding as a repair, however, sanding is neither an effective nor lasting repair for customer complaints of brake roughness or noise. ACTION: Machine brake rotors and drums instead of sanding to help reduce brake roughness caused by one of the following conditions: ^ Rotor thickness variation and lateral runout ^ Lining or foreign material build-up ^ Drum out-of-round NOTE: DO NOT MACHINE OR SAND ROTORS/DRUMS TO REDUCE OCCASIONAL BRAKE NOISE. IT IS NEITHER AN EFFECTIVE OR LASTING REPAIR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 5437 Brake Drum: Specifications The brake drum must be replaced if the inside diameter is outside the maximum limit. The maximum diameter is stamped on the outside of the brake drum. Drum Diameter Nominal 12.125 in Max. Refinish 12.185 in Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 5438 Brake Drum: Testing and Inspection VISUAL INSPECTION Inspect the drum for cracks. If any large, through-the-drum cracks are located the drum must be replaced. NOTE: Cracks in drums are often difficult to locate. To quickly determine if a drum is cracked lightly drop the drum (from a height of 4-5 inches) onto a flat hard surface. A cracked drum will make a dull thud sound while a good drum will make a ringing sound. Inspect for signs of overheating. An overheated drum will often be discolored (blue/gold), warped, or heat checked. Heat checks are small cracks in the drum friction surface. Heat checks can be removed by resurfacing. NOTE: The cause of the overheating should be determined prior to replacing the brake shoes or drums. Inspect for scoring. Any grooves or scores in excess of 0.008 inches should be resurfaced. SPECIFICATIONS - See: Specifications MAXIMUM DIAMETER Purpose The thickness of the drum friction surface is directly proportional to the drums ability to absorb and release heat during braking. As the drum becomes thinner due to normal wear and resurfacing it looses its ability to absorb and release heat and is more prone to brake fade, distortion, and cracking. As the drum wears the inside diameter of the drum increases. The amount of drum thickness lost to wear is equal to 1/2 the increase in diameter. How To Measure A brake drum micrometer is used to measure the drum diameter. - The micrometer scale should be initially set to the original (new) thickness of the drum. - The base of the micrometer should be placed in the deepest groove in the drum and held steady while the measuring point is swiveled to find the maximum diameter. - The base and measuring point should be kept at the same depth in the drum. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 5439 Drum Micrometer - The measurement should be repeated at 3 or more places around the circumference of the drum to determine if the drum is out of round. If the measurements differ by more than 0.004 inches the drum should be resurfaced. NOTE: A drum which is out of round will cause a pedal pulsation to be felt upon braking. - The measurement should also be repeated at various depths of the drum to check for a bellmouth condition. If the measurements differ by more than .010 inches the drum should be resurfaced. For additional information on how to use a drum micrometer see Fundamentals and Basics. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal and Installation Brake Drum: Service and Repair Removal and Installation For additional information see Notes, Warnings, and Hints. REMOVAL 1. Raise the vehicle so the wheel is clear of the floor. Install safety stands under the axle. CAUTION: Use of a drum puller or a torch Is not recommended. Drum distortion may result. 2. Remove the wheel and tire assembly. Remove the spring retaining nuts and remove the brake drum. 3. If the brake drum is rusted to the axle shaft pilot diameter, use coarse sandpaper to remove the rust build-up, then remove the brake drum. 4. Check the surface of the brake drum. If worn or if brake drum is suspected of having excessive runout, the brake drum should be machined. After machining, check maximum diameter (stamped on the outside of the brake drum). Brake drum must be replaced if diameter is outside maximum limit. Retracting Brake Shoes If the brake drum will not come off, insert a narrow screwdriver through the brake adjusting hole in the brake backing plate, and disengage the brake shoe adjusting lever from the brake adjuster screw. While holding the brake shoe adjusting lever away from the brake adjuster screw, loosen the brake adjuster screw with the brake adjusting tool. Loosen the brake adjuster screw only if the brake drum cannot be removed. Do not burr, chip, or damage the notches in the brake adjuster screw or the self-adjusting mechanism will not function properly. If the brake adjuster screw was loosened, check to be sure the brake shoe adjusting lever is still properly seated In the shoe web. INSTALLATION 1. Remove the protective coating from a new brake drum with brake parts cleaner. 2. Adjust the brakes. 3. Install the brake drum onto the axle shaft flange or rear hub. 4. Install the retaining clips securely. Install the wheel on the axle shaft flange or rear hub studs against the brake drum, and tighten to specification. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal and Installation > Page 5442 Brake Drum: Service and Repair Servicing Minor scores should be removed with sandpaper. Grooves and large scores can only be removed by machining with special equipment, as long as the braking surface is within specifications stamped on brake drum outer surface. Any brake drum sufficiently out of round to cause vehicle vibration or noise while braking, or showing taper should also be machined, removing only enough stock to true up the brake drum. After a brake drum is machined, wipe braking surface diameter with a cloth soaked in denatured alcohol. If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Lining Thickness (Primary) 0.22 in Lining Thickness (Secondary) 0.283 in Lining Length (Primary) 11.57 in Lining Length (Secondary) 13.05 in Area Per Brake (Primary) 40.49 in Area Per Brake (Secondary) 45.67 in Total Area Per Brake 86.17 sq in Total Area Per Axle 172.34 sq in Swept Area per Axle 266.64 sq in Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Automatic Adjustment Brake Shoe: Adjustments Automatic Adjustment The brake drums (1126) are automatically adjusted while driving the vehicle in reverse and sharply applying the brakes and then driving forward. It may be necessary to do this several times to obtain the proper rear brake adjustment. Manual brake adjustment is required only after the rear brake shoes and linings (2200) have been relined or replaced, or if adjuster has malfunctioned. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Automatic Adjustment > Page 5448 Brake Shoe: Adjustments Manual Adjustment Fig. 1 Drum Brake Assembly Fig. 3 Left Rear 10 Inch Drum The rear brake shoes, Figs. 2 and 3, adjust automatically when the vehicle is driven forward or reverse and the brakes are applied sharply several times. Manual adjustment is required only when brake shoes are replaced. When adjusting rear brakes, ensure that parking brake is properly adjusted and that equalizer is operating freely. With Drums Removed 1. With drums removed, clean areas where shoes contact backing plate, then apply suitable lubricant to these contact areas, ensuring that lubricant does not contaminate linings. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Automatic Adjustment > Page 5449 2. Using suitable brake shoe adjusting gauge, adjust gauge to inside diameter of brake drum. Fig. 4 Checking Brake Lining Clearance 3. Reverse tool and adjust shoes until they contact gauge, ensuring that gauge is parallel to vehicle and at centerline of axle, Fig. 4. Holding automatic adjusting lever aside, rotate adjusting screw as necessary. 4. Install drums, wheels and retaining nuts, then complete adjustment by applying brakes several times while driving vehicle in reverse. 5. Check brake operation by making several stops in forward gear. Repeat step 4, if necessary. With Drums Installed 1. Raise and support rear of vehicle. 2. Remove cover from adjusting hole located at bottom of backing plate. Fig. 5 Adjusting Rear Drum Brakes 3. Using a small screwdriver to hold adjusting lever away from star wheel, rotate adjusting screw star wheel until brake shoes are locked against drum, Fig. 5. 4. Back-off brake adjusting screw approximately 10 to 12 notches so that brake drum rotates freely without drag. If brake drum does not rotate freely, remove drum and clean and inspect drum brake components. 5. After adjusting both drum brakes lower vehicle and apply brakes several times to position brake shoes. 6. Road test vehicle to ensure brakes operate properly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation Brake Shoe: Service and Repair Installation Rear Web Ledge Brake Assembly ITEM PART DESCRIPTION NUMBER 1 20310-S Rear Wheel Cylinder Retaining Bolt (2 Req'd) 2 55690-S7 Locknut 3 2211 Brake Backing Plate 4 2262 Rear Wheel Cylinder 5 2A642 Primary Brake Shoe Parking Brake Lever Link 6 2A601 Parking Brake Link Spring 7 2A637 Rear Parking Brake Lever 8 2106 Parking Brake Lever Pin Retainer 9 2027 Parking Brake Lever Bolt 10 2219 Secondary Shoe Assembly 11 2A179 Cable Guide 12 2068 Brake Shoe Hold Down Spring 13 2108 Adjusting Lever Pin 14 2A180 Adjusting Lever Return Spring 15 2A176 Brake Shoe Adjusting Lever 16 2047 Brake Shoe Adjusting Screw Nut 17 2049 Brake Shoe Adjusting Screw Spring Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 5452 18 2041 Brake Adjuster Screw 19 2200 Primary Shoe Lining 20 2068 Brake Shoe Hold Down Spring 21 2200 Primary Shoe 22 2296 Brake Shoe Retracting Spring 23 2A178 Brake Shoe Adjusting Lever Cable 24 2092 Brake Adjusting Hole Cover 25 2069 Brake Shoe Hold Down Spring Pin INSTALLATION 1. Clean the ledge pads on the brake backing plate. 2. Apply a lithium-base grease, Premium Long-Life Grease XG-1-C or -K (ESA-M1C75-B) or equivalent or Disc Brake Caliper Lubricant D7AZ-19590-A (ESA-M1C172A) or equivalent to the contacts of the brake shoe retracting spring and the brake shoe hold down spring on the rear brake shoes and linings and brake backing plate. 3. Apply a lithium-base grease, Premium Long-Life Grease XG-1-C or -K (ESA-M1C75-B) or equivalent or Disc Brake Caliper Lubricant D7AZ-19590-A (ESA-M1C172A) or equivalent to the threads and socket end of the brake adjuster screw. 4. Install the upper brake shoe retracting spring on the primary and secondary rear brake shoes and linings as shown above. 5. Position the rear brake shoe and lining on the brake backing plate with the push rods of the rear wheel cylinder in the slots of the rear brake shoe and lining. 6. Install the brake shoe hold down springs. Use Hold Down Spring Tool T73T-2300-A. 7. Install the brake adjuster screw with the slot in the head of the brake adjuster screw toward the primary rear brake shoe and lining. 8. Install the lower brake shoe retracting spring, adjusting lever return spring, adjusting lever assembly (part of brake shoe adjusting lever kit), and connect the rear parking brake cable to the adjusting lever. Brake Adjusting Screw NOTE: Install the brake adjuster screws in the same locations from which they were removed. Interchanging them from one side of the vehicle to the other will cause the rear brake shoes and linings to retract rather than expand each time the automatic adjusting mechanism is operated. To prevent incorrect installation, the socket end of each adjusting screw is stamped with an R or L to indicate their installation on the right or left side of the vehicle. The adjusting pivot nuts can be distinguished by the number of lines machined around the body of the nut. Two lines indicate a right-hand nut; one line indicates a left-hand nut. 9. Position the brake shoe adjusting lever cable in the cable guide and install the cable anchor fitting on the anchor pin. 10. Install the rear parking brake cable in the anchor pin and washer and secure with the retaining nut behind the brake backing plate. 11. Adjust the brakes before installing the brake drums. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 5453 Brake Shoe: Service and Repair Removal Rear Web Ledge Brake Assembly ITEM PART DESCRIPTION NUMBER 1 20310-S Rear Wheel Cylinder Retaining Bolt (2 Req'd) 2 55690-S7 Locknut 3 2211 Brake Backing Plate 4 2262 Rear Wheel Cylinder 5 2A642 Primary Brake Shoe Parking Brake Lever Link 6 2A601 Parking Brake Link Spring 7 2A637 Rear Parking Brake Lever 8 2106 Parking Brake Lever Pin Retainer 9 2027 Parking Brake Lever Bolt 10 2219 Secondary Shoe Assembly 11 2A179 Cable Guide 12 2068 Brake Shoe Hold Down Spring 13 2108 Adjusting Lever Pin 14 2A180 Adjusting Lever Return Spring 15 2A176 Brake Shoe Adjusting Lever 16 2047 Brake Shoe Adjusting Screw Nut 17 2049 Brake Shoe Adjusting Screw Spring Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 5454 18 2041 Brake Adjuster Screw 19 2200 Primary Shoe Lining 20 2068 Brake Shoe Hold Down Spring 21 2200 Primary Shoe 22 2296 Brake Shoe Retracting Spring 23 2A178 Brake Shoe Adjusting Lever Cable 24 2092 Brake Adjusting Hole Cover 25 2069 Brake Shoe Hold Down Spring Pin REMOVAL 1. Raise the vehicle so the wheels clear the floor and install safety stands under the rear axle (4001). Drum Brake Adjuster 2. Remove the wheel and brake drum. If the brake drum does not clear the rear brake shoes and linings, retract the rear brake shoes and linings where shown. 3. Remove the parking brake lever retaining nut from behind the brake backing plate. 4. Remove the parking brake lever. 5. Remove the brake shoe adjusting lever cable from the anchor pin, cable guide, and brake shoe adjusting lever kit. 6. Remove the brake shoe retracting springs. 7. Remove the brake shoe hold down spring (use Hold-Down Spring Tool Number T73T-2300-A) from each rear brake shoe and lining. 8. Remove the rear brake shoes and linings and brake adjuster screw. 9. Disassemble the brake adjuster screw. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 5455 Self Adjusting Brake Assembly ITEM PART DESCRIPTION NUMBER 1 2261 Rear Wheel Cylinder 2 2200 Rear Brake Shoe and Lining Secondary 3 2A179 Cable Guide 4 2A637 Parking Brake Lever 5 2A178 Brake Shoe Adjusting Lever Cable 6 -- Over Travel Spring (Part of 2A178) 7 2A176 Brake Shoe Adjusting Lever Kit 8 2047 Brake Shoe Adjusting Screw Nut 9 2200 Rear Brake Shoe and Lining Primary 10 2049 Brake Shoe Adjusting Screw Spring 11 2068 Brake Shoe Hold Down Spring 12 2296 Brake Shoe Retracting Spring 13 2028 Brake Shoe Anchor Pin Guide Plate 14 2027 Parking Brake Lever Bolt 15 4001 Rear Axle 16 2248 Bolt 17 384568-S100 Retainer Clamp (DRW Vehicles Use Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 5456 Retaining Bracket) 18 34449-S312 Nut 19 351453-S8 Washer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Diagrams Wheel Cylinder: Diagrams Item Part Number Description 1. - Boot 2. 2196 Wheel Cylinder Piston 3. - Piston Cup 4. 2261 Rear Wheel Cylinder 5. 2208 Wheel Cylinder Bleeder Screw 6. 2204 Wheel Cylinder Piston Cup Spring Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Diagrams > Page 5460 Wheel Cylinder: Testing and Inspection NOTE: If dirt is found in any part of the hydraulic system, flush the entire system with clean isopropyl alcohol. 1. Clean all brake cylinder parts in clean isopropyl alcohol or use the Rotunda Brake Parts Washer model 065-00016 or equivalent. 2. Inspect all parts for wear or damage. Check the cylinder bore for rust, scores or other damage. 3. Be sure the bleeder screw passage is clean and open. 4. Replace all parts that are worn or damaged. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal Wheel Cylinder: Service and Repair Removal REMOVAL 1. Raise vehicle on hoist and position suitable safety stands under vehicle. 2. Remove wheel. 3. Remove the wheel, brake drum, and rear brake shoes and linings. Remove the wheel cylinder brake shoe links (2042). 4. Disconnect the rear brake tube (2267) from the rear wheel cylinder. 5. Remove the brake cylinder retaining bolts and lockwashers, and then remove the rear wheel cylinder from the brake backing plate. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 5463 Wheel Cylinder: Service and Repair Rebuild NOTE: For additional information see Fundamentals and Basics. Rear Wheel Cylinder DISASSEMBLY 1. Remove the rubber boots from the ends of the brake cylinder. 2. Remove the pistons, cups and piston cup spring. 3. Remove the wheel cylinder bleeder screw. Ensure the bleeder screw is not plugged. ASSEMBLY 1. Coat all wheel cylinder parts with clean brake fluid or brake assembly lube. 2. Install the bleeder screw into the wheel cylinder. 3. Place the wheel cylinder piston cup spring, cups and pistons into the wheel cylinder. 4. Install a boot and wheel cylinder brake shoe link over each end of the wheel cylinder. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 5464 Wheel Cylinder: Service and Repair Installation INSTALLATION 1. Place the rear wheel cylinder on the brake backing plate and install the retaining bolts and lockwashers. 2. Install a new gasket on the brake line fitting (if equipped) and connect the rear brake tube to the rear wheel cylinder. 3. Install the rear brake shoes and linings and the wheel cylinder brake shoe links. Install the brake backing plate and the wheel. 4. Adjust the brakes and perform brake bleeding procedure. Check pedal operation before moving the vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding NOTE: Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from hydraulic system. 1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to absorb escaping brake fluid. 2. Depress brake pedal slowly forcing air trapped in master cylinder out at fitting. 3. Hold pedal down and tighten fittings, then release brake pedal. NOTE: Releasing brake pedal before fittings are tightened will allow air to enter the master cylinder. 4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm. 5. Bleed brakes as follows: RR, LR, ABS valve, RF, LF 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, 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 the Rear Antilock Brake System (RABS) valve. 7. Bleed the front brakes using same procedure as for rear brakes. 8. Fill master cylinder to 1/4 inch from top of reservoir or to the proper fill line indicated on the fluid reservoir. 9. Centralize pressure differential control valve, if applicable, as follows: a. Turn ignition switch to ACC or ON position. b. Push brake pedal down, allow piston to center itself, turning off warning light. c. Turn ignition switch to the OFF position. 10. Check brake operation and ensure pedal is firm, road test vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5470 Brake Bleeding: Service and Repair Master Cylinder Bleeding 1. Support the master cylinder body in a vise, and fill both fluid reservoirs with heavy duty DOT 3 brake fluid. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake outlet system first. 3. Loosen the plug in the front brake outlet port. Depress the secondary piston slowly to force the air out of the master cylinder. Tighten plug while piston is depressed or air will enter the master cylinder. 4. Repeat this procedure until air ceases to exit at the outlet port. 5. Repeat steps 3 and 4 for the rear brake outlet port with the front brake outlet plugged. 6. Tighten the plugs and try to depress the piston. Depressing the piston should be harder after all air is expelled. 7. Install the plastic cap. 8. Install the master cylinder in the vehicle and bleed the hydraulic system. NOTE: For additional information see Notes, Warnings, and Hints. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5471 Brake Bleeding: Service and Repair Pressure Bleeding Be sure the bleeder tank contains enough of the specified brake fluid to complete the bleeding operation. Charge the tank with approximately 69-206 kPa (10-30 psi). Never exceed 345 kPa (50 psi). Never use brake fluid that has been drained from the hydraulic system. Bleed the longest lines first 1. Clean all dirt from the master cylinder reservoir cap. 2. Remove the master cylinder reservoir cap and fill the master cylinder reservoir with the specified brake fluid. Install the pressure bleeder adapter tool on the master cylinder, and attach the bleeder tank hose to the fitting on the adapter. NOTE: Master cylinder pressure bleeder adapter tools are available from the manufacturers of pressure bleeding equipment. Follow the manufacturer's instructions when installing the adapter. 3. Place a 3/8 inch box wrench on the bleeder fitting on the right rear brake wheel cylinder. Attach a bleeder tube snugly to the bleeder fitting. 4. Open the valve on the bleeder tank and admit pressurized brake fluid to the master cylinder reservoir. 5. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen the bleeder fitting. 6. When air bubbles no longer appear in the fluid at the submerged end of the bleeder tube, close the bleeder fitting and remove the tube. 7. Repeat Steps 3 through 6 at the opposite wheel cylinder. On front brakes, bleed the right front caliper first. 8. When the bleeding operation is completed, close the bleeder tank valve and remove the tank hose from the adapter fitting. 9. Remove the pressure bleeder adapter tool. Fill the master cylinder reservoirs with the specified brake fluid to within 3 mm (1/8 in) from the top of the filler neck. Install the master cylinder cover. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5472 Brake Bleeding: Service and Repair Priming Brake System When a brake master cylinder (2140) has been installed, or the brake system emptied or partially emptied, fluid may not flow from the wheel cylinder bleeder screws during normal bleeding. It may be necessary to prime the brake master cylinder using the following procedure: 1. Use a tubing wrench to remove the front brake tube (2264) and the brake master cylinder outlet rear tube from the brake master cylinder. 2. Install short brake tubes in the brake master cylinder and position them so that they curve into the brake master cylinder reservoir, and the ends of the tubes are submerged in brake fluid. 3. Fill the brake master cylinder reservoir (2K478) with new Ford High-Performance DOT 3 Brake Fluid C6AZ-19542-AA or -BA or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 4. Have an assistant pump the brakes until clear, bubble-free fluid flows from both brake tubes. 5. Remove the short brake tubes and reinstall the front brake tube and brake master cylinder outlet rear tube (2B253) on the brake master cylinder. 6. Bleed each brake tube at the brake master cylinder using the following procedure: a. Have an assistant pump the brake pedal (2455) 10 times and then hold firm pressure on the brake pedal. b.Loosen the rearmost brake tube fittings with a tubing wrench until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal until the brake tube fitting is tightened again. c. Repeat this operation until clear, bubble-free fluid comes out from around the tube fitting. Refill the brake master cylinder reservoir as necessary. d. Repeat this bleeding operation at the front brake tube fittings. 7. If any of the brake tubes, disc brake calipers (2B120), or rear wheel cylinders have been removed, it may be helpful to prime the system by gravity bleeding. This should be done after the brake master cylinder is primed and bled. To gravity bleed the brake system: a. Fill the brake master cylinder with new Heavy-Duty Brake Fluid C6AZ-19542-AA or -BA or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. b. Loosen both of the wheel cylinder bleeder screws and leave them open until clear brake fluid flows. Be sure to check the brake master cylinder reservoir fluid level often and do not let it run dry. c. Tighten the wheel cylinder bleeder screws (2208) to 7-9 Nm (61-87 in lb). d. One at a time, loosen the caliper bleeder screws. Leave the bleeder screws open until clear fluid flows. Check the fluid level often in the brake master cylinder reservoir and do not let it run dry. e. Tighten the caliper bleeder screws to 17-24 Nm (12-17 ft lb). 8. After the brake system has been primed, bleed the brake system at each wheel (1007). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5473 Brake Bleeding: Service and Repair With ABS SPECIAL TOOLS NEEDED Description Tool Number Antilock Brake Adapter (Bleeder Box) T90P-50-ALA Antilock Brake Adapter T93T-50-ALA (Jumper Cable) EEC-IV Breakout Box T83L-50-EEC-IV CAUTION: Perform this procedure only if the Hydraulic Control Unit (HCU) has been replaced. Follow conventional bleed procedures if the HCU is not being replaced. 1. Perform conventional brake system bleed. 2. Connect Antilock Brake Adapter T90P-50-ALA (bleeder box) and Antilock Brake Adapter T93T-50-ALA (jumper cable). 3. Press down on the brake pedal (2455) and depress the VALVES button on the bleeder box ( brake pedal will fall). 4. Release the VALVES button and release the brake pedal. 5. Repeat above two steps once more. 6. Depress the MOTOR START button and let the pump motor run for one minute. 7. Perform conventional brake system bleed. ANTILOCK BRAKE ADAPTER CONTROLS Item Part Number Description 1 T90P-50-ALA Anti-Lock Brake Adapter (Part of T90P-50-ALA) 2 -- Bleed/Harness Selector (Part of T90P -50-ALA) 3 -- Green "Motor On" Lamp (Part of T90P -50-ALA) 4 -- Red "Motor Off" Lamp (Part of T90P-50-ALA) 5 -- Valve Button (Part of T90P-50-ALA) 6 -- Abort Button (Part of T90P-50-ALA) 7 -- Motor Start Button (Part of T90P-50-ALA) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Slide Bolts 22-26 ft.lb Caliper Anchor Mounting Bolts 85-100 ft.lb Brake Hose Block Bolt 10-15 ft.lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 5477 Brake Caliper: Diagrams Caliper Exploded View NOTE: Both caliper pistons are located on the inboard side and function exactly as a single piston unit. Dual pistons are used to produce higher braking forces (due to the greater total piston surface area). They also result in more uniform application of the larger brake pads used on these trucks. ITEM PART NUMBER DESCRIPTION 1. 2196 Wheel Cylinder Piston. 2. - Piston Boot (Part of 2B120). 3. - Piston Seal (Part of 2B120). 4. 2B120 Front Disc Brake Caliper. 5. 2B164 Disc Brake Pad Anti-Rattle Clip. 6. 2001 Brake Shoe and Lining. 7. - Bleeder Screw (Part of 2B120). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 5478 Brake Caliper: Testing and Inspection NOTE: When raising the vehicle make sure that the hoist lift points do not rest on the caliper pins. 1. Raise vehicle on hoist. 2. Remove the wheel and tire from the front disc brake hub and rotor (1102). 3. Visually check the disc brake caliper (2B120). If the disc brake caliper housing is leaking, it should be replaced. If a caliper piston (2196) is leaking, the caliper disc brake caliper must be disassembled and new caliper piston installed. If a caliper piston is seized in the bore, a new disc brake caliper housing is required. CAUTION: Do not pry on plastic caliper piston with a screwdriver or other tools, as this will cause chipping. 4. If a disc brake caliper caliper piston is removed for any reason, the piston seal must be replaced. Exercise care not to damage plastic caliper piston by protecting it from contact with any metal or sharp objects. 5. Clean all metal parts with isopropyl alcohol. Then, clean out and dry the grooves and passageways with compressed air. Make sure that caliper bore and component parts are thoroughly clean and dry prior to assembly. 6. Check the cylinder bore and caliper piston for excessive scoring or corrosion. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front DISASSEMBLY Dual Piston Brake Caliper 1. Drain the fluid from the cylinders. 2. Secure the caliper assembly in a vise. 3. Place a block of wood between the caliper bridge and the cylinders, and apply low pressure air to the brake hose inlet. The pistons will be forced out to the wood block. Removing Caliper Piston 4. Remove the wood block, and remove the pistons. 5. Remove and discard the piston seals and boots. 6. If the caliper assembly is leaking, replace the piston assemblies. If the cylinder bores are scored, corroded or excessively worn, replace the caliper. Do not hone the cylinder bores. Piston assemblies are not available for oversize bores. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5481 CLEANING and INSPECTION Clean all metal parts with isopropyl alcohol. Clean out and dry the grooves and passageways with compressed air. Make sure that caliper bore and component parts are thoroughly clean. Use a wire brush to remove any rust or corrosion from the machined surfaces of the caliper housing. NOTE: Do not use a wire brush in the cylinder bore. Check the cylinder bore and piston for damage or excessive wear. Replace the piston if it is pitted, scored or worn. Do not replace phenolic pistons for cosmetic surface irregularities or small chips between the piston groove and pad face. Use a wire brush to clean corrosion from the boot groove and the machined surfaces of the spindle assembly. Replace the anti-rattle clip, piston seal and dust boot with new components. ASSEMBLY NOTE: Never re-use piston seals and dust boots. Install a new set each time the caliper is assembled. 1. Lubricate new piston seals with clean brake fluid. Install them in the seal grooves in the cylinder bores. 2. Apply a film of clean brake fluid to the cylinder bores. 3. Lubricate retaining lips of the dust boots with clean brake fluid and install them in the boot retaining grooves in the cylinder bores. 4. Apply a film of clean brake fluid to the pistons. 5. Insert the pistons into the dust boots and start them into the cylinders by hand until they are beyond the piston seals. Be careful not to damage or dislodge the piston seal. 6. Place a wood block over one piston and press the piston into the cylinder being careful not to cock the piston in the cylinder. Install the second piston in the same manner. Make certain that boots are correctly seated. 7. Install the pad and lining assemblies and anti-rattle spring in the caliper assembly. Place the caliper assembly on the support and install the caliper pins. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5482 Brake Caliper: Service and Repair Inspection For additional information see Installation Notes. See: Fundamentals and Basics 1. Install caliper slide pins through disc brake caliper and front wheel spindle. Tighten bolts to 30-36 Nm (22-26 lb ft). 2. If front brake hose was removed, replace both washers (each side of inlet block). Connect the front brake hose. Tighten inlet block bolt to 14-20 Nm (10-15 lb ft). Perform brake bleeding procedures. 3. Install wheel and tire assembly. Remove the safety stands and lower the vehicle. 4. If the brakes were not bled, and disc brake caliper was not removed check the fluid level in the brake master cylinder reservoir and fill if required. 5. Pump the brakes several times to make sure you get a firm brake pedal. 6. Operate the vehicle to check brake operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5483 Brake Caliper: Service and Repair Removal For additional information see Removal Notes. See: Fundamentals and Basics 1. To avoid fluid overflow when the caliper pistons are pressed into the caliper cylinder bores, remove part of the brake fluid out of the brake master cylinder reservoir. Discard the removed fluid. 2. Raise the vehicle on a hoist and install safety stands. Remove the wheel and tire assembly. NOTE: When raising the vehicle make sure that the hoist lift points do not rest on the caliper pins. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5484 Bottoming Caliper Pistons 3. Place an appropriate size C-clamp on the disc brake caliper with end of clamp against caliper and end of screw against outer pad. Tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the C-clamp. NOTE: Do not use a screwdriver or similar tool to pry the caliper piston away from the front disc brake hub and rotor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5485 Removing Caliper Assembly 4. Remove both caliper slide pins. Examine the slide pins to assure that they are not damaged. Replace if necessary. 5. Remove the disc brake caliper assembly. Remove brake pad linings. CAUTION: Do not let the disc brake caliper hang by the brake hose. The brake hose could become stretched or twisted, which can cause the front brake hose to leak and rupture. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5486 Removing Caliper Assembly 6. If the disc brake caliper is to be removed for repair or replacement, disconnect the front brake hose from the disc brake caliper. Plug the end of the front brake hose to prevent fluid loss and the entry of air into the system. If the disc brake caliper is not to be removed, secure it to the frame of the vehicle to avoid damage to the front brake hose. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes Brake Caliper: Fundamentals and Basics Removal Notes When Removing the Caliper, Remember... - Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir is only 1/3 full. - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining thickness between wheels on the same axle will result in a strong steering pull when the brakes are applied. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. - When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is forced back into the caliper, these deposits will be forced back through the brake lines and into the master-cylinder. - When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a glass or plastic jar to catch the expelled fluid. - Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses can be damaged easily by this practice. These hoses are double walled, damage to the interior pressure hose will not be visible. - Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not attempt to insert the piston back into the caliper. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 5489 Brake Caliper: Fundamentals and Basics Installation Notes WHEN INSTALLING CALIPERS AND PADS, REMEMBER... - Clean and lubricate caliper slide joint/pins with high temperature silicone grease: Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted movement of the caliper slide assemblies to release the brakes. If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon the release of the brake pedal. This will result in overheated brakes and premature brake wear. Disc Brake Mechanical Force Diagram NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel forces the inner pad against the rotor, then further travel forces the movable part of the caliper to pull the outer pad against the rotor. High temperature silicone lubricant must be used. Low temperature grease can melt and contaminate the pads and rotors, or can bake into a very hard substance which binds the slides. Petroleum based grease can cause the slide boots to soften and swell. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. Anti-squeal Coating - Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an insulator to dampen high frequency vibrations that are generated during normal braking. These compounds are highly effective in preventing brake squeal. - Many professional repair shops recommend always rebuilding or replacing the calipers when replacing the brake linings, because: When the pistons are forced back into the calipers, the piston seals are dragged across any corrosion or abrasives that may be deposited on the inside of the caliper. Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston is gradually withdrawn from the caliper. This results in the piston seals again being dragged across the layer of corrosion and deposits. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 5490 Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking. - Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck bleeder screw is much easier with the caliper removed from the vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Brake Fluid Boiling Point Chart Brake Fluid: Specifications Brake Fluid Boiling Point Chart One of the key aspects of brake fluid quality is the temperature at which it boils. A comparison of the boiling points for DOT 3 (in general), Ford DOT 3 and DOT 5 brake fluids is shown. If brake fluid boils in the brake system, it forms vapor which reduces the ability of the brake system to develop hydraulic line pressure. If brake fluid boils, the system acts just like a system with air in the lines, except that it reverts to normal operation when the brakes cool and the vapor condenses. BRAKE FLUID BOILING POINTS MINIMUM FEDERAL SAFETY STANDARDS Dry Wet Dry Wet DOT 3 401° 284° 205° 140° DOT 5 500° 356° 260° 180° Ford 550° 550° 288° 288° DOT 3 Exceeds Exceeds Exceeds Exceeds Require- Require- Require- Requirements ments ments ments NOTE: A newly opened can exceeds all minimum requirements. Brake fluid absorbs moisture out of the air and must be stored in the original container with the cap securely fastened. If not, its moisture content will increase and the boiling point will drop. Moisture also will be absorbed while the fluid is in the brake system, but a properly capped and sealed brake master cylinder reservoir (2K478) will limit the rate at which this occurs. NOTE: For more brake fluid information see Fundamentals and basics. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Brake Fluid Boiling Point Chart > Page 5495 Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. Brake Fluid DOT 3 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 5496 Brake Fluid: Testing and Inspection Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. The color of the brake fluid in a normal brake system in Service can vary from its original color for many reasons. Sometimes a brake master cylinder (2140) may show significantly different shades of color of brake fluid in the brake master cylinder reservoir (2K478). Some of the reasons for the apparent difference in color in a system are listed below. ^ Brake fluid discoloration can occur due to heat and/or aging. ^ Brake fluid discoloration can exist when different brands/shades of brake fluid are used in topping off during normal Service. ^ Brake fluid discoloration can occur through the dissolving of color dye used on brake master cylinder internal springs in manufacturer's assembly procedure. NOTE: Brake fluid contaminated with a hydrocarbon/mineral based fluid (power steering or transmission fluid) can be detected by an obvious swelling of the brake master cylinder filler cap gasket. If the swollen gasket condition is present, all brake system rubber parts must be replaced. All brake tubes must be thoroughly flushed with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or DOT 3 equivalent fluid meeting Ford specification ESA-M6C25-A before the vehicle goes back into Service. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Fluid Level Sensor, ABS Brake Fluid Level Sensor/Switch: Description and Operation Fluid Level Sensor, ABS Master Cylinder Reservoir PURPOSE The Master Cylinder Reservoir with Low Fluid Level Warning Switch monitors the fluid level in the master cylinder. OPERATION When a low fluid level condition occurs, a path to ground is provided through the dual brake warning switch to disable the Antilock brake system and illuminate the Antilock brake indicator. CONSTRUCTION The low fluid level warning switch is an integral part of the brake master cylinder reservoir. It is serviced as a part of the brake master cylinder reservoir. It consists of a float and magnet assembly and a reed switch. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Fluid Level Sensor, ABS > Page 5501 Brake Fluid Level Sensor/Switch: Description and Operation Fluid Level Sensor, Brakes PURPOSE The brake fluid level switch closes with low brake fluid level. When closed, a ground is applied to the brake indicator and the lamp will illuminate. NOTE: The brake fluid level sensor is part of the master cylinder reservoir and is not serviced separately. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 5502 Brake Fluid Level Sensor/Switch: Service and Repair The brake master cylinder sensor is part of the brake master cylinder reservoir and is not separately serviceable. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications 3/8-24 Thread ...................................................................................................................................... ............................................. 13-20 Nm (10-15 ft lb) 7/16-24 Thread .................................................................................................................................... ............................................. 13-20 Nm (10-15 ft lb) 1/2-20 Thread ...................................................................................................................................... ............................................. 20-28 Nm (15-21 ft lb) 9/16-18 Thread .................................................................................................................................... ............................................. 20-28 Nm (15-21 ft lb) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Brake Hose Brake Hose/Line: Description and Operation Brake Hose Flexible hoses connect the brake tube to the front brake cylinders and to the rear brake tube connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Brake Hose > Page 5508 Brake Hose/Line: Description and Operation Brake Line WARNING: Copper tubing should not be used in the hydraulic system. Use only sae j526 or j527 steel tubing, or equivalent. NOTE: If a section of the brake tube is damaged, Replace the entire section with tubing of the same type, size, shape, and length. Be careful not to kink or crack the tubing when bending it to fit the frame or rear-axle forms. Steel tubing is used in the front brake tube (2264) between the brake master cylinder and the front brake tube connector, between the rear brake tube connector and the rear brake cylinders and between the brake master cylinder along the frame rail to the flexible hose connected to the rear brake tube connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection > Brake Hose Brake Hose/Line: Testing and Inspection Brake Hose Replace a flexible brake hose if it shows signs of softening, cracking or other damage. When installing a new brake hose, position the hose to avoid contact with other vehicle parts. The wet appearance of the outer cover of rubber brake hoses is called "sweating". This is a normal condition for neoprene rayon braid hose. The "sweating" condition is not evidence of a brake fluid leak and will not result in a loss of pressure in the system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection > Brake Hose > Page 5511 Brake Hose/Line: Testing and Inspection Brake Line Inspect the brake tubes and hoses under the vehicle for damage and proper routing. Check the brake hoses routed to the disc brake calipers (2B120), and/or to the rear wheel cylinders (2261) for any signs of damage. The tube and hose fittings must be tight without signs of leakage. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Flaring Brake Hose/Line: Service and Repair Flaring Flaring A Tube (Flaring-Bar Type) CAUTION: Copper tubing should not be used in the hydraulic system. Use only SAE J526 or J527 steel tubing, or equivalent. NOTES: - If a section of the brake tube is damaged, replace the entire section with steel brake tubing of the same type, size, shape, and length. Be careful not to kink or crack the tubing when bending to fit the frame or rear axle forms. - Double flare brake tubing as described below should provide good leak-proof connections. Always clean the inside of a new brake tube with clean isopropyl alcohol. 1. Cut off and straighten the required length of tube. A tubing cutter tool will simplify making a clean and square cut. 2. Square off the ends of the tube with a file, and chamfer the end of the tube to be flared. 3. Insert the tube through appropriate ribbed hole in the bar assembly until the end of the tube sticks out about as far as the thickness of the adapter above the bar, or even with the bar, depending on the tool used. 4. Fit the adapter onto the tube and slide the bar into the yoke. Lock the bar in position with the tube beneath the yoke screw. 5. Form the single flare by tightening the yoke screw securely. 6. Release the screw and remove the adapter. 7. Form the double flare by tightening the yoke screw again, with the second adapter fitted, depending on the tool used. 8. Release the screw bar and flared tube. 9. Inspect the flare for cracks or poor flare form and repeat the process if the flare is not correct. Flaring A Tube (Split-Die Type) CAUTION: Copper tubing should not be used in the hydraulic system. Use only SAE J526 or J527 steel tubing, or equivalent. NOTES: - If a section of the brake tube is damaged, replace the entire section with steel brake tubing of the same type, size, shape, and length. Be careful not to kink or crack the tubing when bending to fit the frame or rear axle forms. - Double flare brake tubing as described below should provide good leak-proof connections. Always clean the inside of a new brake tube with clean isopropyl alcohol. 1. Cut off and straighten the required length of tube. NOTE: A tubing cutter tool will simplify making a clean and square cut. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Flaring > Page 5514 2. Square off the ends of the tube with a file, and chamfer the end of the tube to be flared. 3. Select the split die for the tube to be used and insert the die into the tapered hole in the body. 4. Push the tube through the die until the tube is even with the face of the die. Lock the tube in this position by tightening the wing nut securely. 5. The punches are marked Op. 1 and Op. 2. Slide the first operation punch into the hole in the center of the body and tighten the screw securely to form the single flare. 6. Release the screw and replace the first operation punch with the second operation punch and tighten the screw to form the double flare. 7. Release the screw, wing nut, punch, and dies. 8. Remove the tube and inspect the flare for cracks or poor flare form. If the flare is not correct, cut it off and repeat the process. NOTE: The finished flare must be square with the tube, free of cracks and have a smooth mating surface to make sure the connection is leak-proof. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Flaring > Page 5515 Brake Hose/Line: Service and Repair Service Procedure Steel tubing is used in the hydraulic lines between the brake master cylinder and the front brake tube connector and between the rear brake tube connector and the rear wheel cylinders. Steel tubing is also used to connect the brake master cylinder to the rear brake hose at the rear axle. Flexible hoses connect the brake tube to the disc brake calipers and to the rear brake tube connector. When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After replacement, bleed the brake system at the rear wheel cylinders and at the brake master cylinder. Refer to Brake Bleeding. Rear Brake Tube Hose Connector WARNING: Copper tubing should not be used in the hydraulic system. Use only sae J526 or J527 steel tubing, or equivalent. NOTE: If a section of the brake tube is damaged, Replace the entire section with tubing of the same type, size, shape, and length. Be careful not to kink or crack the tubing when bending it to fit the frame or rear-axle forms. Double flare brake tubing as described below should provide good leakproof connections. NOTE: Always clean the inside of a new brake tube with clean isopropyl alcohol. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation Proportioning Valve PURPOSE A proportioning valve, where used, is integral to the master cylinder. It proportions pressure to the rear system. OPERATION The brake pressure control valve regulates the hydraulic pressure in the rear brake system. It is located between the rear brake system's inlet and outlet ports in the main valve. When the brake pedal (2455) is applied, the full brake fluid pressure passes through the brake pressure control valve to the rear brake system until the valve's split point is reached. Above its split point, the brake pressure control valve begins to reduce the hydraulic pressure to the rear brakes, creating a balanced braking condition between the front and rear wheels to minimize rear wheel lock-up during hard braking. In case of the front brake system malfunction, the brake master cylinder fluid control valve has a bypass feature, which allows full hydraulic pressure to the rear brake system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 5519 Brake Proportioning/Combination Valve: Testing and Inspection If there is a brake system concern such as premature rear brake lockup, that cannot be attributed to the Rear Antilock Brake System (RABS), the cause may be a malfunctioning brake master cylinder fluid control valve. Check the brake master cylinder fluid control valve by substituting the suspected bad valve with a known good one. If the condition persists, recheck the RABS. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 5520 Brake Proportioning/Combination Valve: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect the brake tube from the outlet port at the rear of the brake master cylinder. 2. Unscrew the brake master cylinder fluid control valve and remove it from the brake master cylinder. 3. To install, reverse the removal procedure. Tighten the brake tube-to-brake master cylinder fitting to 21.2-28.8 Nm (16-21 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Locations Hydraulic Control Assembly - Antilock Brakes: Locations Item Part Number Description 1 N807514 Screw 2 5005 Frame 3 W611645-S100 Screw, M10-1.5 x 25.5 4 2234 Front Inlet Tube (Primary) 5 2234 Front Inlet Tube (Secondary) 6 2C286 Hydraulic Control Unit 7 2B112 Intermediate Brake Tube 8 2263 Front Brake Tube (RH) 9 2264 Front Brake Tube (LH) 10 383057-S Union 11 2B373 Anti-Lock Brake Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Connector Views 4 Wheel Anti-Lock Brakes Hydraulic Unit Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Diagrams > Connector Views > Page 5526 Hydraulic Control Assembly - Antilock Brakes: Mechanical Diagrams Item Part Number Description 1 2005 Power Brake Booster 2 -- Outlet, Front Right (Part of 2C286) 3 -- Outlet, Front Left (Part of 2C286) 4 -- Outlet, Rear Axle (Part of 2C286) 5 2C286 Anti-Lock Hydraulic Control Unit 6 -- Pump Motor (Part of 2C286) 7 2140 Brake Master Cylinder Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Brake Pressure Modulator Valve Hydraulic Control Assembly - Antilock Brakes: Description and Operation Brake Pressure Modulator Valve PURPOSE The components of the Rear Anti-Lock Brake System (RABS) valve work together to control pressure to the rear wheel cylinders, inhibiting rear wheel lockup. CONSTRUCTION The RABS valve contains an accumulator, dump solenoid, and an isolation valve. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Brake Pressure Modulator Valve > Page 5529 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Assembly OPERATION Sensing a potential wheel lockup, the Rear Antilock Brake (RABS) module will activate the isolation solenoid within the RABS valve assembly, isolating the rear wheel cylinders from the master cylinder, so that brake pressure cannot increase. If pickup potential is still present with the isolation valve activated, the RABS module will energize the dump solenoid within the RABS valve assembly with rapid pulses to bleed off wheel cylinder fluid into an accumulator built into the RABS valve assembly, reducing rear wheel speed and allowing the rear wheels to spin back up to vehicle speed. The isolation and dump solenoids will continue to be pulsed by the RABS module to keep the rear wheels rotating during braking. When the brake pedal is released, the isolation valve assembly de-energizes and any brake fluid in the accumulator is returned to the master cylinder. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Brake Pressure Modulator Valve > Page 5530 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Pressure Regulating Valve, ABS PURPOSE The brake pressure control valve regulates the hydraulic pressure in the rear brake system. OPERATION When the brake pedal is applied, the full brake fluid pressure passes through the brake pressure control valve to the rear brake system until the valve's split point is reached. Above its split point, the brake pressure control valve begins to reduce the hydraulic pressure to the rear brakes, creating a balanced braking condition between the front and rear wheels to minimize rear wheel lockup during hard braking. CONSTRUCTION The brake pressure control valve is an integral part of the brake master cylinder, located between the rear brake system's inlet and outlet ports in the main valve. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve REMOVAL 1. Disconnect the inlet and outlet brake lines from the RABS valve. 2. Disconnect the wiring harness from the RABS valve. 3. Remove the three screws retaining the RABS valve to the frame rail liner and remove the RABS valve. INSTALLATION 1. Position the RABS valve on the frame side rail. Install the three screws and tighten to 26-32 N-m (19-24 lb-ft). 2. Connect the wiring harness connector to the RABS valve. 3. Connect the brake lines to the RABS valve and tighten as follows: a. 1/2-20 threaded fitting -- 14-23 Nm (10-17 lb ft). b. 7/16-24 threaded fitting -- 14-20 Nm (10-15 lb ft). CAUTION: Do not overtighten the fittings. 4. Perform system brake bleeding procedure. NOTE: It is not necessary to energize the RABS valve electrically to bleed the rear brakes. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve > Page 5533 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Assembly REMOVAL 1. Disconnect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect 12-pin connector attaching Hydraulic Control Unit (HCU) to wire harness, and disconnect 2-pin connector attaching pump motor to harness. 3. Remove two tubes from inlet ports and three tubes from outlet ports of HCU. Plug each port to prevent brake fluid from spilling on paint and wiring. NOTE: HCU assembly bracket contains locating hooks on top of the frame. The assembly must be lifted prior to pulling it away from the frame. 4. Remove three nuts retaining HCU assembly and remove assembly from vehicle. INSTALLATION CAUTION: HCU is not interchangeable with other units. Be sure to replace with correct part. 1. Insert HCU assembly into mounting bracket. Install three retaining nuts and tighten to 16-24 Nm (12-18 ft lb). 2. Connect three tubes to outlet ports on side of HCU and two tubes to inlet ports on front of HCU. Tighten tube fittings to 14-24 Nm (10-18 ft-lb). 3. Connect 12-pin connector and 8-pin connector to harness. 4. Connect positive battery cable. 5. Perform system brake bleeding procedures. Check for fluid leaks. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Fluid Reservoir Brake Master Cylinder: Description and Operation Brake Fluid Reservoir Master Cylinder Reservoir PURPOSE The Master Cylinder Reservoir with Low Fluid Level Warning Switch monitors the fluid level in the master cylinder. OPERATION When a low fluid level condition occurs, a path to ground is provided through the dual brake warning switch to disable the Antilock brake system and illuminate the Antilock brake indicator. CONSTRUCTION The low fluid level warning switch is an integral part of the brake master cylinder reservoir. It is serviced as a part of the brake master cylinder reservoir. It consists of a float and magnet assembly and a reed switch. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Fluid Reservoir > Page 5538 Brake Master Cylinder: Description and Operation Master Cylinder, Brakes OPERATION The dual master cylinder performs in the following manner: Rear wheel brakes - are connected to the secondary outlet port and are actuated by the secondary piston assembly. Front wheel brakes - are connected to the primary outlet port (nearest the dash panel) and are actuated by the primary piston assembly. NOTE: Both primary and secondary pistons function together. The dual master cylinder contains a plastic "seethru" fluid reservoir with a Fluid Level Indicator (FLI) and primary and secondary hydraulic pistons and an integral proportioning valve. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Master Cylinder: Initial Inspection and Diagnostic Overview Fluid Level Check Brake fluid level in the master cylinder reservoir should be between 4mm (0.16 inch) below the MAX line on the side of the reservoir and the MAX line. If brake fluid is low, the red BRAKE indicator will illuminate. To add brake fluid, clean and remove cap and pour clean brake fluid into the top of the reservoir. Fill to specification mentioned above. Use Heavy-Duty Brake Fluid C6AZ-19542-AA (ESA-M6C25-A) or DOT 3 equivalent. If brake fluid has to be added often, check all hydraulic connections for leaks. Inspection INSPECTION Inspect for Leakage NOTE: The master cylinder should be cleaned thoroughly prior to inspection (several days preferably). Spilled brake fluid can be easily confused with leakage. Piston Seals Leakage around the piston seals will seep out from the end of the cylinder and leak down the outside of the brake booster. - Inspect for signs of seepage or bubbled paint on the brake booster. If any leakage is detected the master cylinder should be replaced or overhauled Brake Line Fittings While someone is applying pressure to the brake pedal, inspect the brake line fittings on the master cylinder for leakage. - If the fittings are leaking they should be disassembled and inspected. Reservoir to Cylinder Gasket Inspect the gasket for signs of leakage or hardening and cracking. - Overhaul or replace the master cylinder if any leakage is indicated. Inspect for Oil Contamination. - Inspect the rubber gasket on the inside of the master cylinder lid. If the gasket is swollen or bloated, the brake fluid is contaminated with oil. - Siphon or scoop a small amount of brake fluid out of the master cylinder and place into a styrofoam cup filled 2/3 of the way with water. Brake fluid will mix with the water while oil contaminants will float on the surface and dissolve the styrofoam. NOTE: If any oil contamination is present ALL brake components containing rubber seals will need to be replaced or overhauled. This includes the master cylinder, both front brake calipers, both rear wheel cylinders, and all flexible brake hoses. Verify Hold-Down Bolts Are Tight - While someone is applying and releasing pressure to the brake pedal, verify the the master cylinder is tightly secured to the brake booster. - Retighten hold-down bolts if necessary. Functional Checks NOTE: Always bleed the entire brake system and verify the rear brakes are properly adjusted prior to diagnosing a master cylinder as defective. For additional information see Master Cylinder / Brake Pedal Relationship. Check Related Systems Check for proper brake booster operation 1. With the engine "OFF", depress and release the brake pedal 4-5 times (this bleeds off the vacuum reserve in the booster). 2. Depress the brake pedal firmly and start the engine. If the pedal goes down slightly the brake booster is assisting in brake operation. If the pedal does not go down slightly the brake booster is not assisting in brake operation and should be diagnosed for problems. - Check and adjust rear brakes. - Check all brake lines and brake assemblies for leakage. Repair all deficiencies with related systems prior to diagnosing the master cylinder as defective. Check Brake Pedal Travel (Non-Antilock Brake Systems Only) Fully depress the brake pedal and check for the following: The pedal should have a 75% reserve. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5541 Pedal Reserve Checks - The pedal should be firm and not leak down. Replace the master cylinder if all of the following conditions exist: The brake pedal is not firm with a 75% reserve and - There were no problems with any of the related systems and - The entire brake system has been bled and - The rear brakes are properly adjusted. Abnormal Conditions Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system. Refer to Symptom Charts for abnormal condition diagnosis. Normal Conditions The following conditions are considered normal and are not indications that the brake master cylinder is in need of service. Condition 1: During normal operation of the master cylinder, the fluid level in the brake master cylinder reservoir will rise during brake application and fall during release. The net fluid level, i.e., after brake application and release, will remain unchanged. Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal. Condition 3: Fluid level will decrease with pad wear. Inspection INSPECTION Inspect for Leakage NOTE: The master cylinder should be cleaned thoroughly prior to inspection (several days preferably). Spilled brake fluid can be easily confused with leakage. Piston Seals Leakage around the piston seals will seep out from the end of the cylinder and leak down the outside of the brake booster. - Inspect for signs of seepage or bubbled paint on the brake booster. If any leakage is detected the master cylinder should be replaced or overhauled Brake Line Fittings While someone is applying pressure to the brake pedal, inspect the brake line fittings on the master cylinder for leakage. - If the fittings are leaking they should be disassembled and inspected. Reservoir to Cylinder Gasket Inspect the gasket for signs of leakage or hardening and cracking. - Overhaul or replace the master cylinder if any leakage is indicated. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5542 Inspect for Oil Contamination. - Inspect the rubber gasket on the inside of the master cylinder lid. If the gasket is swollen or bloated, the brake fluid is contaminated with oil. - Siphon or scoop a small amount of brake fluid out of the master cylinder and place into a styrofoam cup filled 2/3 of the way with water. Brake fluid will mix with the water while oil contaminants will float on the surface and dissolve the styrofoam. NOTE: If any oil contamination is present ALL brake components containing rubber seals will need to be replaced or overhauled. This includes the master cylinder, both front brake calipers, both rear wheel cylinders, and all flexible brake hoses. Verify Hold-Down Bolts Are Tight - While someone is applying and releasing pressure to the brake pedal, verify the the master cylinder is tightly secured to the brake booster. - Retighten hold-down bolts if necessary. Functional Checks NOTE: Always bleed the entire brake system and verify the rear brakes are properly adjusted prior to diagnosing a master cylinder as defective. For additional information see Master Cylinder / Brake Pedal Relationship. Check Related Systems Check for proper brake booster operation 1. With the engine "OFF", depress and release the brake pedal 4-5 times (this bleeds off the vacuum reserve in the booster). 2. Depress the brake pedal firmly and start the engine. If the pedal goes down slightly the brake booster is assisting in brake operation. If the pedal does not go down slightly the brake booster is not assisting in brake operation and should be diagnosed for problems. - Check and adjust rear brakes. - Check all brake lines and brake assemblies for leakage. Repair all deficiencies with related systems prior to diagnosing the master cylinder as defective. Check Brake Pedal Travel (Non-Antilock Brake Systems Only) Fully depress the brake pedal and check for the following: The pedal should have a 75% reserve. Pedal Reserve Checks - The pedal should be firm and not leak down. Replace the master cylinder if all of the following conditions exist: The brake pedal is not firm with a 75% reserve and - There were no problems with any of the related systems and - The entire brake system has been bled and - The rear brakes are properly adjusted. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5543 Brake Master Cylinder: Component Tests and General Diagnostics Bypass Conditions Test For the bypass condition test, refer to Pinpoint Test R. Compensator Port Test The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake master cylinder reservoir. The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. If turbulence is seen in the brake master cylinder reservoir upon release of the brake pedal, this is normal and shows that the compensating ports are not plugged. Fluid Level Check Brake fluid level in the master cylinder reservoir should be between 4mm (0.16 inch) below the MAX line on the side of the reservoir and the MAX line. If brake fluid is low, the red BRAKE indicator will illuminate. To add brake fluid, clean and remove cap and pour clean brake fluid into the top of the reservoir. Fill to specification mentioned above. Use Heavy-Duty Brake Fluid C6AZ-19542-AA (ESA-M6C25-A) or DOT 3 equivalent. If brake fluid has to be added often, check all hydraulic connections for leaks. Non-Pressure Leaks The only part of the brake system that could have a brake fluid loss that did not appear when the system is under pressure is the brake master cylinder reservoir area. Brake fluid loss could be caused by a missing or poorly-fitted brake master cylinder filler cap (2162), from a punctured or otherwise damaged brake master cylinder reservoir, by a missing or damaged brake master cylinder filler cap gasket or by missing, damaged or poorly fitted sealing grommets between the brake master cylinder (2140) and the brake master cylinder reservoir. The brake master cylinder reservoir grommets are not separately serviceable and must be replaced with a new brake master cylinder reservoir. NOTE: The wet appearance of the outer cover of rubber brake hoses is called "sweating." This is a normal condition for neoprene rayon braid hose. The "sweating" condition is not evidence of a brake fluid leak and will not result in a loss of pressure in the system. Replace a flexible brake hose if it shows signs of softening, cracking or other damage. When installing a new brake hose, position the hose to avoid contact with other vehicle parts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 5544 Brake Master Cylinder: Adjustments Fig.1 Checking Master Cylinder Pushrod Length Check the distance from the outer end of the booster assembly push rod to the front face of the brake booster assembly. Turn the push rod adjusting screw in or out as required to obtain the specified length. NOTE: For additional information see Push Rod Adjustment Notes. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir Brake Master Cylinder: Service and Repair Brake Fluid Reservoir REMOVAL WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Disconnect the battery ground cable. 2. Disconnect the brake warning lamp indicator wire from the brake master cylinder reservoir fluid level indicator socket. Using a suitable suction device, drain the brake fluid from the brake master cylinder reservoir. 3. Using a large screwdriver, pry between the brake master cylinder reservoir and the brake master cylinder and remove the brake master cylinder reservoir. INSTALLATION NOTE: Whenever replacing the brake master cylinder reservoir, Replace the grommets. 1. Lubricate the two grommets included in service kit with DOT 3 Brake Fluid C6AZ-19542-AA or DOT 3 equivalent fluid meeting Ford specification ESA-M6C25-A. Insert the grommets into the brake master cylinder. 2. Press the brake master cylinder reservoir into the grommets with the fluid level indicator socket facing outboard. The brake master cylinder reservoir should snap in place. 3. Connect the brake warning lamp indicator wire to the fluid level indicator socket. 4. Connect the battery ground cable. 5. Fill the brake master cylinder reservoir with DOT 3 Brake Fluid C6AZ-19542-AA or DOT 3 equivalent fluid meeting Ford specification ESA-M6C25-A. Bleed the system. Refer to Brake Bleeding. 6. After brake bleeding, fill brake master cylinder reservoir to 3.17mm (0.125 in) from the top with DOT 3 Brake Fluid C6AZ-19542-AA or DOT 3 equivalent fluid meeting Ford Specification ESA-M6C25-A. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 5547 Brake Master Cylinder: Service and Repair Master Cylinder, Brakes Cleaning 1. Clean all master cylinder parts in clean isopropyl alcohol, or use the Rotunda Brake Parts Washer model 065-00016 or equivalent and inspect the parts for wear or damage. Replace if required. When a master cylinder repair kit is used, follow the instructions in the kit and install all of the parts provided. 2. Make sure that all ports and vents in the master cylinder are open and free of foreign matter. Rebuild Master Cylinder Exploded View Item Part Number Description 1 2162 Brake Master Cylinder Filler Cap 2 -- Float (Part of 2L454) 3 2K478 Brake Master Cylinder Reservoir 4 -- Brake Master Cylinder Grommets (Part of 2L454) 5 2140 Brake Master Cylinder 6 -- Stop Bolt (Part of 2140) 7 -- Primary Piston (Part of 2004) 8 -- Snap Ring (Part of 2004) 9 -- Secondary Piston (Part of 2004) 10 2C161 Brake Master Cylinder Fluid Control Valve REMOVAL 1. Remove the brake master cylinder from the vehicle. 2. Clean the outside of the brake master cylinder. Remove the brake master cylinder filler cap and gasket. Drain and discard any brake fluid that remains in the brake master cylinder. 3. If equipped, remove the brake master cylinder fluid control valve from the brake master cylinder. 4. Remove stop-bolt from the bottom of the brake master cylinder. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 5548 Snap Ring 5. Depress the primary piston and remove snap ring from retaining groove at the rear of the brake master cylinder bore. 6. Remove primary piston assembly from the brake master cylinder bore. Discard assembly. 7. 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. Discard assembly. 8. Inspect the brake master cylinder bore for signs of etching, pitting, scoring or other damage. a. If bore is damaged, discard and replace with new brake master cylinder. Do not attempt to hone bore. b. If bore is not damaged, rebuild brake master cylinder using the proper repair kit and the procedure below. INSTALLATION 1. Clean the brake master cylinder body with clean isopropyl alcohol to remove any contamination. 2. Dip the repair kit piston assemblies in clean High-Performance DOT 3 Brake Fluid C6AZ-19542-AA or -BA or DOT 3 equivalent meeting Ford specification ESA-M6C25-A to lubricate seals. 3. Carefully insert the complete secondary piston assembly in the brake master cylinder bore. 4. Carefully insert the primary piston assembly in the brake master cylinder bore. 5. Depress the primary piston and install the snap ring in the groove in the brake master cylinder bore. 6. Install the stop-bolt into the bottom of the brake master cylinder. 7. If equipped, install the brake master cylinder fluid control valve into the brake master cylinder. 8. Install the brake master cylinder filler cap on the brake master cylinder reservoir. Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. REMOVAL 1. Disconnect the battery ground cable. 2. With the engine turned off, push the brake pedal down to expel vacuum from the power brake booster. 3. Disconnect fluid level indicator switch connector from the brake master cylinder. 4. Disconnect the rear brake master cylinder outlet tube and front brake master cylinder outlet tube from the brake master cylinder. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 5549 5. Remove the nuts retaining brake master cylinder to power brake booster. Remove the brake master cylinder from the power brake booster. Item Part Number Description 1 2140 Brake Master Cylinder 2 2005 Power Brake Booster 3 2234 Brake Master Cylinder Outlet Tube (Front) 4 2234 Brake Master Cylinder Outlet Tube (Rear) 5 382984 Clamp 6 382802-S2 Nut A -- Tighten to 21-28 Nm (16-21 lb ft) INSTALLATION 1. Before installing the brake master cylinder, check the distance from the outer end of the booster assembly push rod, to the front face of the power brake booster. 2. Using a shop fabricated gauge, adjust the power brake booster push rod so that the end is 24.89-25.27mm (0.980-0.995 in.) from the face of the power brake booster. Item Part Number Description 1 -- Shop Fabricated Gauge Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 5550 2 -- Adjustment Screw (Part of 2005) A -- 24.89-25.27mm (0.980-0.995 in.) B -25.27mm (0.995 in.) C -- 19.05mm (0.75 in.) D -- 74.61mm (2.94 in.) 3. Position the brake master cylinder assembly over the booster push rod and onto the two studs on the power brake booster. 4. Install the attaching nuts and tighten 21-28 Nm (16-21 lb ft). 5. Loosely connect the rear brake master cylinder outlet tube and front brake master cylinder outlet tube to the brake master cylinder. 6. Tighten the rear outlet tube fitting to 15-20 Nm (11-14 lb ft) and the front outlet tube fitting to 21-28 Nm (16-21 lb ft). 7. Connect fluid level indicator switch. 8. Connect the battery ground cable. 9. Bleed the brake master cylinder. Refer to Brake Bleeding. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Page 5551 Brake Master Cylinder: Tools and Equipment BASIC SERVICE (Removal and Installation) - Fender cover (servicing and bleeding a master-cylinder can be a messy process) CAUTION: DOT 3 or 4 brake fluid is very corrosive to the vehicles finish and electrical connections. - Drip pan. - Complete set of combination wrenches or sockets. - Brake bleeding device: - Pressure bleeder or - Vacuum bleeder or - One-man brake bleeder kit or - Length of clear plastic hose (3/16 inch ID) and a glass jar. Brake Bleeding Setup - Small ruler or depth gauge (for adjusting the pushrod) - Brake adjusting tool (rear brake adjustment should be checked) - Clean shop towels. OPTIONAL - Master Cylinder brake bleeding kit (contains plastic fittings and hoses used for bleeding master cylinders) - Suction bulb (for removing brake fluid from reservoir) IF MASTER-CYLINDER IS OVERHAULED - Snap-ring pliers - Small pry bar (for separating the reservoir from the cylinder) - Cylinder hone (cast iron cylinders only) - Feeler gauges (for checking piston to cylinder clearance). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Diagrams Wheel Cylinder: Diagrams Item Part Number Description 1. - Boot 2. 2196 Wheel Cylinder Piston 3. - Piston Cup 4. 2261 Rear Wheel Cylinder 5. 2208 Wheel Cylinder Bleeder Screw 6. 2204 Wheel Cylinder Piston Cup Spring Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Diagrams > Page 5555 Wheel Cylinder: Testing and Inspection NOTE: If dirt is found in any part of the hydraulic system, flush the entire system with clean isopropyl alcohol. 1. Clean all brake cylinder parts in clean isopropyl alcohol or use the Rotunda Brake Parts Washer model 065-00016 or equivalent. 2. Inspect all parts for wear or damage. Check the cylinder bore for rust, scores or other damage. 3. Be sure the bleeder screw passage is clean and open. 4. Replace all parts that are worn or damaged. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal Wheel Cylinder: Service and Repair Removal REMOVAL 1. Raise vehicle on hoist and position suitable safety stands under vehicle. 2. Remove wheel. 3. Remove the wheel, brake drum, and rear brake shoes and linings. Remove the wheel cylinder brake shoe links (2042). 4. Disconnect the rear brake tube (2267) from the rear wheel cylinder. 5. Remove the brake cylinder retaining bolts and lockwashers, and then remove the rear wheel cylinder from the brake backing plate. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 5558 Wheel Cylinder: Service and Repair Rebuild NOTE: For additional information see Fundamentals and Basics. Rear Wheel Cylinder DISASSEMBLY 1. Remove the rubber boots from the ends of the brake cylinder. 2. Remove the pistons, cups and piston cup spring. 3. Remove the wheel cylinder bleeder screw. Ensure the bleeder screw is not plugged. ASSEMBLY 1. Coat all wheel cylinder parts with clean brake fluid or brake assembly lube. 2. Install the bleeder screw into the wheel cylinder. 3. Place the wheel cylinder piston cup spring, cups and pistons into the wheel cylinder. 4. Install a boot and wheel cylinder brake shoe link over each end of the wheel cylinder. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 5559 Wheel Cylinder: Service and Repair Installation INSTALLATION 1. Place the rear wheel cylinder on the brake backing plate and install the retaining bolts and lockwashers. 2. Install a new gasket on the brake line fitting (if equipped) and connect the rear brake tube to the rear wheel cylinder. 3. Install the rear brake shoes and linings and the wheel cylinder brake shoe links. Install the brake backing plate and the wheel. 4. Adjust the brakes and perform brake bleeding procedure. Check pedal operation before moving the vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 95S10 > May > 95 > Recall - Parking Brake Front Cable Technical Service Bulletin # 95S10 Date: 950501 Recall - Parking Brake Front Cable 95S10 SAFETY RECALL Certain 1995 Model Year Completed Econoline E250 and E350 Commercial Stripped Chassis' Parking Brake Front Cable Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Customer Notification Letter Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. Please Note Correct all vehicles in stock before delivery. Federal Law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,000 per vehicle. Promptly Correct Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. Dealer-Owner Contact Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. Region Contact Advise regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Parts and Service Zone Manager about all matters. Claims Submission For dealers NOT on ACESII, submit 1864 claims using DWE for all completed vehicles. Your may use your original 1863 for your record file copy. For dealers on ACESII, submit claims via DWE. Warranty And Policy Manual For dealers NOT on ACESII, see your Warranty and Policy Manual for claims preparation. For dealers on ACESII, see Sections 5 and 6 of the ACESII manual. Attachment II - Labor and Parts Information Parking Brake Front Cable Affected Vehicles: 1995 Model Year E250-350 Commercial Chassis Labor Allowances For Dealers NOT on ACESII OPERATION DESCRIPTION LABOR TIME LABOR CODE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 95S10 > May > 95 > Recall - Parking Brake Front Cable > Page 5569 Replace Front Parking Brake Cable Only or Front 0.7 Hrs. Insert in Box "B" on Form 1864 and Intermediate Parking Brake Cables (Includes adjust parking brake) Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Labor Allowances for Dealers on ACESII Submit using DWE. OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Replace Front Parking Brake Cable Only or Front 0.7 Hrs. Labor Operation 95S10B and Intermediate Parking Braking Brake Cable (includes adjust parking brake) Administrative Allowance 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. APPLICATION PART NUMBER DESCRIPTION DEALER PRICE KIT AA (*) F2UZ-2853-A ONLY Front Cable $37.68 (1 per vehicle) KIT BB (**) F5UZ-2A793-AA and Extension Cable $17.41 F2UZ-2853-A Front Cable (1 of each cable per affected vehicle) (*) - Only 27 units affected nationally. See VIN list attached. (**) - Only 80 units affected nationally. See VIN list attached. Parts prices current until next issue of Master Price Book. For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book Attachment III - Technical Information Parking Brake Front Cable Technical Instructions Affected Vehicles: 1995 Model Year E250-350 Commercial Chassis Reference: 1995 Model Year Econoline Body, Chassis Service Manual, Section 06-05 Remove Front Braking Brake Cable: Refer to Section 06-05-07 thru 10 Installation: Refer to Section 06-05-10 Kit Code AA: Install Front Cable Kit F2UZ-2853-A only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 95S10 > May > 95 > Recall - Parking Brake Front Cable > Page 5570 Kit Code BB: Install Front Cable Kit F2UZ-2853-A and Extension Cable Kit F5UA-2A793-A Dealer Letter PARTS AVAILABILITY RECALL NUMBER 95S10 Date: May, 1995 At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers At PDC By: Now Date in Owner Letter: May, 1995 To: Selected Ford Dealers Subject: Safety Recall 95S10 - Certain 1995 Model Year Completed Econoline E250 and E350 Commercial Stripped Chassis' - Parking Brake Front Cable Affected Vehicles Certain 1995 model year completed Econoline E250 and E350 Commercial stripped chassis' produced from 12/23/94 through 1/24/95 at Lorain Assembly Plant. Reasons For Recall Federal Motor Vehicle Safety Standard No. 105, specifies that the affected vehicles shall be equipped with a parking brake system capable of holding the vehicle stationary for 5 minutes, in both the forward and reverse direction, on a 20 percent grade. The parking brake front cables installed by Ford on the affected chassis' are approximately 1.6 inches longer than intended. As a result, the effectiveness of the parking brake on a severe grade may be diminished, and vehicles may not fully comply with the above noted FMVSS 105 requirement. To correct this condition, the parking brake front cable with be replaced. In addition, as an interim measure, certain units built with this condition were fitted, prior to shipment, with a parking brake intermediate extension cable that was modified (shortened) to compensate for the longer that intended front cable. This resulted in a correctly functioning and compliant brake system; however, to maintain uniformity for future servicing, these vehicles with have the parking brake front cable and also the intermediate extension cable replaced. Refer to the VIN list for the appropriate repair and required parts for each vehicle. Questions? Claims Information 1-800-423-8851 (Warranty Assistance Team) Technical Assistance 1-800-826-4694 (Technical Hotline) Other Recall Questions 1-800-325-5621 (Renkim) Attachments Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > 95S10 > May > 95 > Recall - Parking Brake Front Cable > Page 5571 Owner Letter May, 1995 Serial Number: 12345678901234567 95S10 Mr. John Sample 123 Main Street Anywhere, USA 12345 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that certain 1995 model year Econoline E250 and E350 Completed Commercial Chassis vehicles may fail to conform to Federal Motor Vehicle Safety Standard No. 105, "Hydraulic Brake Systems". Non-Compliance Federal Motor Vehicle Safety Standard No. 105, specifies that the affected vehicles shall be equipped with a parking brake system capable of holding the vehicle stationary for five (5) minutes, in both the forward and reverse directions, on a 20 percent grade. The parking brake front cables installed by Ford on the affected chassis are not of the length intended. As a result, the effectiveness of the parking brake on a severe grade may be diminished, and vehicles may not fully comply with the above noted FMVSS 105 requirement. Repairs At no charge to you, your dealer will replace the parking brake cable. Dealers currently have instructions and parts ordering information. How Long Will It Take? The time needed for this service is about one hour. However, due to service scheduling times, your dealer may need your vehicle for one full working day. Call Your Dealer Call your dealer without delay. Ask for a service date and whether parts are in stock for Safety Recall 95S10. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your vehicle in, show the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address Or Sold The Vehicle? Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the vehicle. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center, 300 Renaissance Center, P. O. Box 43360, Detroit, Michigan 48243. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington, D.C. area residents may call 366-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford built Econoline chassis. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Recalls for Parking Brake Cable: > NHTSA95V058000 > Mar > 95 > Recall 95V058000: Parking Brake Cable Defect Parking Brake Cable: Recalls Recall 95V058000: Parking Brake Cable Defect THE PARKING BRAKE FRONT CABLES WERE BUILT LONGER THAN APPROPRIATE THAT REDUCES THE PERFORMANCE OF THE PARKING BRAKE IN CERTAIN CIRCUMSTANCES, AND FAILS TO FULLY COMPLY WITH ALL THE REQUIREMENTS OF FMVSS NO. 105, "HYDRAULIC BRAKE SYSTEMS." CONSEQUENCE OF NON-COMPLIANCE: THE EFFECTIVENESS OF THE PARKING BRAKE SYSTEM ON A SEVERE GRADE MAY BE DIMINISHED. DEALERS WILL REPAIR THE PARKING BRAKE SYSTEM ON THE AFFECTED VEHICLES. SYSTEM: EMERGENCY PARKING BRAKE; MECHANICAL; LINKAGES AND CABLES, FMVSS NO. 105. VEHICLE DESCRIPTION: INCOMPLETE CHASSIS VEHICLES. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED FREE OF CHARGE WITHIN A REASONABLE TIME, PLEASE CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1995 FORD TRUCK ECONOLINE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 95S10 > May > 95 > Recall - Parking Brake Front Cable Technical Service Bulletin # 95S10 Date: 950501 Recall - Parking Brake Front Cable 95S10 SAFETY RECALL Certain 1995 Model Year Completed Econoline E250 and E350 Commercial Stripped Chassis' Parking Brake Front Cable Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Customer Notification Letter Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. Please Note Correct all vehicles in stock before delivery. Federal Law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,000 per vehicle. Promptly Correct Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. Dealer-Owner Contact Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. Region Contact Advise regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Parts and Service Zone Manager about all matters. Claims Submission For dealers NOT on ACESII, submit 1864 claims using DWE for all completed vehicles. Your may use your original 1863 for your record file copy. For dealers on ACESII, submit claims via DWE. Warranty And Policy Manual For dealers NOT on ACESII, see your Warranty and Policy Manual for claims preparation. For dealers on ACESII, see Sections 5 and 6 of the ACESII manual. Attachment II - Labor and Parts Information Parking Brake Front Cable Affected Vehicles: 1995 Model Year E250-350 Commercial Chassis Labor Allowances For Dealers NOT on ACESII OPERATION DESCRIPTION LABOR TIME LABOR CODE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 95S10 > May > 95 > Recall - Parking Brake Front Cable > Page 5581 Replace Front Parking Brake Cable Only or Front 0.7 Hrs. Insert in Box "B" on Form 1864 and Intermediate Parking Brake Cables (Includes adjust parking brake) Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Labor Allowances for Dealers on ACESII Submit using DWE. OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Replace Front Parking Brake Cable Only or Front 0.7 Hrs. Labor Operation 95S10B and Intermediate Parking Braking Brake Cable (includes adjust parking brake) Administrative Allowance 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. APPLICATION PART NUMBER DESCRIPTION DEALER PRICE KIT AA (*) F2UZ-2853-A ONLY Front Cable $37.68 (1 per vehicle) KIT BB (**) F5UZ-2A793-AA and Extension Cable $17.41 F2UZ-2853-A Front Cable (1 of each cable per affected vehicle) (*) - Only 27 units affected nationally. See VIN list attached. (**) - Only 80 units affected nationally. See VIN list attached. Parts prices current until next issue of Master Price Book. For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book Attachment III - Technical Information Parking Brake Front Cable Technical Instructions Affected Vehicles: 1995 Model Year E250-350 Commercial Chassis Reference: 1995 Model Year Econoline Body, Chassis Service Manual, Section 06-05 Remove Front Braking Brake Cable: Refer to Section 06-05-07 thru 10 Installation: Refer to Section 06-05-10 Kit Code AA: Install Front Cable Kit F2UZ-2853-A only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 95S10 > May > 95 > Recall - Parking Brake Front Cable > Page 5582 Kit Code BB: Install Front Cable Kit F2UZ-2853-A and Extension Cable Kit F5UA-2A793-A Dealer Letter PARTS AVAILABILITY RECALL NUMBER 95S10 Date: May, 1995 At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers At PDC By: Now Date in Owner Letter: May, 1995 To: Selected Ford Dealers Subject: Safety Recall 95S10 - Certain 1995 Model Year Completed Econoline E250 and E350 Commercial Stripped Chassis' - Parking Brake Front Cable Affected Vehicles Certain 1995 model year completed Econoline E250 and E350 Commercial stripped chassis' produced from 12/23/94 through 1/24/95 at Lorain Assembly Plant. Reasons For Recall Federal Motor Vehicle Safety Standard No. 105, specifies that the affected vehicles shall be equipped with a parking brake system capable of holding the vehicle stationary for 5 minutes, in both the forward and reverse direction, on a 20 percent grade. The parking brake front cables installed by Ford on the affected chassis' are approximately 1.6 inches longer than intended. As a result, the effectiveness of the parking brake on a severe grade may be diminished, and vehicles may not fully comply with the above noted FMVSS 105 requirement. To correct this condition, the parking brake front cable with be replaced. In addition, as an interim measure, certain units built with this condition were fitted, prior to shipment, with a parking brake intermediate extension cable that was modified (shortened) to compensate for the longer that intended front cable. This resulted in a correctly functioning and compliant brake system; however, to maintain uniformity for future servicing, these vehicles with have the parking brake front cable and also the intermediate extension cable replaced. Refer to the VIN list for the appropriate repair and required parts for each vehicle. Questions? Claims Information 1-800-423-8851 (Warranty Assistance Team) Technical Assistance 1-800-826-4694 (Technical Hotline) Other Recall Questions 1-800-325-5621 (Renkim) Attachments Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > 95S10 > May > 95 > Recall - Parking Brake Front Cable > Page 5583 Owner Letter May, 1995 Serial Number: 12345678901234567 95S10 Mr. John Sample 123 Main Street Anywhere, USA 12345 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that certain 1995 model year Econoline E250 and E350 Completed Commercial Chassis vehicles may fail to conform to Federal Motor Vehicle Safety Standard No. 105, "Hydraulic Brake Systems". Non-Compliance Federal Motor Vehicle Safety Standard No. 105, specifies that the affected vehicles shall be equipped with a parking brake system capable of holding the vehicle stationary for five (5) minutes, in both the forward and reverse directions, on a 20 percent grade. The parking brake front cables installed by Ford on the affected chassis are not of the length intended. As a result, the effectiveness of the parking brake on a severe grade may be diminished, and vehicles may not fully comply with the above noted FMVSS 105 requirement. Repairs At no charge to you, your dealer will replace the parking brake cable. Dealers currently have instructions and parts ordering information. How Long Will It Take? The time needed for this service is about one hour. However, due to service scheduling times, your dealer may need your vehicle for one full working day. Call Your Dealer Call your dealer without delay. Ask for a service date and whether parts are in stock for Safety Recall 95S10. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your vehicle in, show the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address Or Sold The Vehicle? Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the vehicle. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center, 300 Renaissance Center, P. O. Box 43360, Detroit, Michigan 48243. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington, D.C. area residents may call 366-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford built Econoline chassis. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Cable: > NHTSA95V058000 > Mar > 95 > Recall 95V058000: Parking Brake Cable Defect Parking Brake Cable: All Technical Service Bulletins Recall 95V058000: Parking Brake Cable Defect THE PARKING BRAKE FRONT CABLES WERE BUILT LONGER THAN APPROPRIATE THAT REDUCES THE PERFORMANCE OF THE PARKING BRAKE IN CERTAIN CIRCUMSTANCES, AND FAILS TO FULLY COMPLY WITH ALL THE REQUIREMENTS OF FMVSS NO. 105, "HYDRAULIC BRAKE SYSTEMS." CONSEQUENCE OF NON-COMPLIANCE: THE EFFECTIVENESS OF THE PARKING BRAKE SYSTEM ON A SEVERE GRADE MAY BE DIMINISHED. DEALERS WILL REPAIR THE PARKING BRAKE SYSTEM ON THE AFFECTED VEHICLES. SYSTEM: EMERGENCY PARKING BRAKE; MECHANICAL; LINKAGES AND CABLES, FMVSS NO. 105. VEHICLE DESCRIPTION: INCOMPLETE CHASSIS VEHICLES. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED FREE OF CHARGE WITHIN A REASONABLE TIME, PLEASE CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1995 FORD TRUCK ECONOLINE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation Parking Brake Cable: Service and Repair Removal and Installation Front REMOVAL 1. Remove the parking brake control and disconnect the front parking brake cable and conduit. Item Part Number Description 1 3B139 Steering Column Support Bracket 2 2780 Parking Brake Control 3 2853 Front Parking Brake Cable and Conduit 4 2A793 Intermediate Cable 5 2A602 Parking Brake Cable Equalizer 6 2C218 Anti-Lock Brake Sensor Wiring Retainer 7 2A635 Parking Brake Rear Cable and Conduit , Right 8 57632-S2 Screw and Washer, Parking Brake Rear Cable and Conduit Clip 9 N804729-S100 Clip 10 2A709 Rear Parking Brake Cable Retainer 11 2A635 Parking Brake Rear Cable and Conduit , Left 12 N620481-S2 Nut, Parking Brake Control-to -Steering Column Support A -- Tighten to 17-23 N-m (13-16 Lb-Ft) B -- Tighten to 17-23 N-m (13-16 Lb-Ft) 2. Remove the front parking brake cable and conduit from the vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation > Page 5590 Item Part Number Description 1 2A635 Parking Brake Rear Cable and Conduit 2 57632-S2 Screw and Washer, Parking Brake Rear Cable and Conduit Clip 3 804729-S100 Clip, Parking Brake Rear Cable and Conduit 4 2A635 Parking Brake Rear Cable and Conduit 5 2A709 Rear Parking Brake Cable Retainer 6 2A602 Parking Brake Cable Equalizer A -- Tighten to 17-23 N-m (13-17 Lb-Ft) INSTALLATION 1. Position the front parking brake cable and conduit in the vehicle,routing the front parking brake cable and conduit through the left stepwell. 2. Install the parking brake control. Intermediate REMOVAL and INSTALLATION 1. Remove the LH cowl side panel. 2. To gain the needed slack have an assistant pull the intermediate cable toward the rear of the vehicle. 3. While the assistant holds the intermediate cable, insert a 4mm (0.156 in) pin into the hole provided in the parking brake control. Parking Brake Control Tension Release 4. Disconnect the intermediate cable from the cable connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation > Page 5591 5. Disconnect the intermediate cable from the parking brake cable equalizer. 6. Remove the intermediate cable from the vehicle. 7. For installation, follow removal procedures in reverse order. Item Part Number Description 1 3B139 Steering Column Support Bracket 2 2780 Parking Brake Control 3 2853 Front Parking Brake Cable and Conduit 4 2A793 Intermediate Cable 5 2A602 Parking Brake Cable Equalizer 6 2C218 Anti-Lock Brake Sensor Wiring Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation > Page 5592 Retainer 7 2A635 Parking Brake Rear Cable and Conduit 8 57632-S2 Screw and Washer, Parking Brake Rear Cable and Conduit Clip 9 N804729-S100 Clip 10 2A709 Rear Parking Brake Cable Retainer 11 2A635 Parking Brake Rear Cable and Conduit 12 N620481-S2 Nut, Parking Brake Control-to -Steering Column Support A -- Tighten to 17-23 N-m (13-16 Lb-Ft) B -- Tighten to 17-23 N-m (13-16 Lb-Ft) Rear REMOVAL 1. Relieve tension on the system by having an assistant pull directly rearward on the intermediate or front parking brake cable and conduit, using care not to damage the coating on the parking brake cable strand, insert a 4mm (0.156 in) or equivalent into the hole provided in the parking brake control. 2. Raise the vehicle and remove the LH or RH as necessary, hub cap, wheel, and brake drum. 3. Disconnect the LH or RH as necessary, parking brake rear cable and conduit from the parking brake cable equalizer. 4. Compress the prongs that retain the parking brake rear cable and conduit shield to the parking brake cable bracket by using a 1/2-inch 12-point box end wrench. 5. With the spring tension released, lift the parking brake rear cable and conduit out of the slot in the parking brake lever. 6. Working on the wheel side, compress the prongs on the cable retainer so they can pass through the hole in the brake backing plate. Draw the rear parking brake cable retainer and the parking brake rear cable and conduit out of the hole. INSTALLATION 1. Push the parking brake rear cable and conduit and the rear parking brake cable retainer through the brake backing plate and through the routing clip (if present) until the end of the parking brake rear cable and conduit can be inserted through the slot in the parking brake lever. 2. Insert the front end of the brake master cylinder push rod bushing through the parking brake cable bracket until the prongs expand. 3. Install the brake drum, wheel, and hub cap, and adjust the rear brakes. 4. Remove the pin inserted in the parking brake control to take up cable slack. 5. Operate the parking brake control three times to verify the parking brake system is functioning properly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation > Page 5593 Parking Brake Assembly to the Equalizer REMOVAL 1. Remove the parking brake control and disconnect the front parking brake cable and conduit. See: Parking Brake Control 2. Remove the front parking brake cable and conduit from the vehicle. Rear Parking Brake Assembly ITEM PART DESCRIPTION NUMBER 1 2A602 Parking Brake Cable Equalizer 2 2A709 Rear Parking Brake Cable Retainer 3 2A809 Parking Brake Rear Cable and Conduit 4 2A635 Parking Brake Rear Cable and Conduit 5 57631 Screw and Washer 17-23 Nm (13-17 ft lb) 6 6N804729-S100 Clip 7 4001 Rear Axle (Reference) 8 2A709 Rear Parking Brake Cable Retainer INSTALLATION 1. Position the front parking brake cable and conduit in the vehicle, routing the front parking brake cable and conduit through the left stepwell. 2. Install the parking brake control. Parking Brake Equalizer to Rear Wheel Rear Parking Brake Assembly ITEM PART DESCRIPTION Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation > Page 5594 NUMBER 1 2A602 Parking Brake Cable Equalizer 2 2A709 Rear Parking Brake Cable Retainer 3 2A809 Parking Brake Rear Cable and Conduit 4 2A635 Parking Brake Rear Cable and Conduit 5 57631 Screw and Washer 17-23 Nm (13-17 ft lb) 6 6N804729-S100 Clip 7 4001 Rear Axle (Reference) 8 2A709 Rear Parking Brake Cable Retainer Parking Brake Control Tension Release REMOVAL 1. Relieve tension on the system by having an assistant pull directly rearward on the intermediate or front parking brake cable and conduit, being careful not to damage the coating on the parking brake cable strand, while you insert a 5/32-inch drill bit or equivalent into the hole provided in the parking brake control. 2. Raise the vehicle and remove the hub cap, wheel and brake drum. 3. Disconnect the parking brake rear cable and conduit to be replaced from the parking brake cable equalizer. 4. Compress the prongs that retain the parking brake rear cable and conduit housing to the frame bracket by using a 1/2-inch 12-point box end wrench. 5. With the spring tension off the parking brake lever, lift the parking brake rear cable and conduit out of the slot in the lever, and remove the parking brake rear cable and conduit through the brake backing plate hole. Rear Parking Brake Cable 6. Working on the wheel side, compress the prongs on the rear parking brake cable retainer (2A709) so they can pass through the hole in the brake backing plate (2211). Draw the rear parking brake cable retainer out of the hole. INSTALLATION 1. Push the parking brake rear cable and conduit through the brake backing plate and through the routing clip (if present) until the end of the parking Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation > Page 5595 brake rear cable and conduit is inserted through the slot in the parking brake lever. 2. Pull the excess slack from the parking brake rear cable and conduit and insert the parking brake rear cable and conduit into the brake backing plate access hole until the retainer prongs expand. 3. Insert the front end of the parking brake rear cable and conduit through the frame bracket until the prong expands. 4. Install the brake drum, wheel, and hub cap, and adjust the rear brake shoes. 5. Remove the drill bit from the parking brake control to tension the system. 6. Cycle the parking brake control three times to verify the parking brake control unit is functioning properly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation > Page 5596 Parking Brake Cable: Service and Repair Tension Release 1. Raise and support the vehicle enough to gain access to the front parking brake cable and conduit or the intermediate cable. 2. Remove the cowl side trim panel. 3. Have an assistant pull and hold the front parking brake cable and conduit or the intermediate cable rearward. Parking Brake Control Tension Release 4. Insert a 4mm (0.156 in.) drill bit or equivalent pin into the hole provided in the parking brake control. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair Parking Brake Control: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the cowl side trim panel. 3. Disconnect the parking brake signal switch and bracket connector at the parking brake control. 4. Remove the three nuts holding the parking brake control to the steering column support bracket. Pull the parking brake control away from the steering column support bracket. 5. Relieve tension on the parking brake system by having an assistant pull directly rearward on the intermediate cable until all front parking brake cable and conduit is unwound from the parking brake control. Be careful not to damage the coating on the parking brake cable. Parking Brake Control Tension Release 6. Insert a 4mm (0.156 in.) drill bit or equivalent size pin into the hole provided in the parking brake control. 7. Raise and support the vehicle. 8. Disconnect the front parking brake cable and conduit from the cable connector. 9. Lower the vehicle and disconnect the barrel end of the front parking brake cable and conduit from the parking brake control. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Page 5600 10. Disconnect the cable conduit from the parking brake control. ^ Inserting a 1/2-inch 12-point box end wrench over the conduit snap fitting to compress the retaining fingers. ^ Back out the snap fitting. 11. Remove the parking brake control from the vehicle. INSTALLATION 1. Route the cable end fitting over the cable shoe. Snap the conduit fitting into the parking brake control. Insert the barrel end into the hole in the track. 2. Position the parking brake control to the steering column support bracket and install the three retaining nuts. Tighten to 17-23 Nm (13-17 lb ft). 3. Raise and support the vehicle. 4. Connect the front parking brake cable and conduit to the cable connector. 5. Lower the vehicle and connect the parking brake signal switch and bracket connector. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Page 5601 6. Carefully remove the drill bit from the parking brake control. 7. Operate the parking brake several times. Rotate both rear wheels to be sure that the parking brakes are not dragging. 8. Install the cowl side panel. 9. Connect the battery ground cable. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Description and Operation Parking Brake Shoe: Description and Operation Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Disassembly and Assembly Parking Brake Shoe: Service and Repair Disassembly and Assembly Brake Shoes Disassembly 1. Holding the brake assembly securely, remove the two brake shoe return springs using a suitable brake spring tool. 2. Spread the free ends of the brake shoes apart and remove the brake shoes from the lower anchor pin. 3. Remove the shoe-to-shoe spring. 4. Clean any grease or contamination from the support plate. Remove contamination from the shoe guide lugs and other shoe bearing surfaces with sandpaper. 5. Coat the following areas with Ford Disc Brake Caliper Slide Grease D7AZ-19590-A or equivalent meeting Ford specification ESA-M1C172-A. Use only a light application of grease at these points. ^ Camshaft lugs and ball of actuating lever. ^ Shoe guide lugs and shoe bearing points of the support plate assembly. ^ Upper and lower anchor pins. ^ Anchor pin contact points of the brake shoes. Assembly 1. Using new parking brake shoes, install new shoe-to-shoe springs into the lower holes of the parking brake shoes. 2. Assemble the lower ends of the parking brake shoes over the shoulder of the lower anchor pin, twisting the parking brake shoes into position. 3. Move the upper ends of the parking brake shoes to the upper anchor pin, inserting the parking brake shoe webs between the shoe guide lugs and the bearing surfaces of the support plate. 4. With the upper ends of the parking brake shoes against the upper anchor pin, install two new shoe return springs. 5. Install the short hooked end of each spring into the upper holes of the parking brake shoes and hook the opposite end of each spring over the anchor pin nib, using a suitable spring installation tool. Be sure the open end of the spring hook faces toward the brake centerline. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Disassembly and Assembly > Page 5607 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Mechanical Specifications Vacuum Brake Booster: Mechanical Specifications Master Cylinder-to-Booster ............................................................................................................................................................ 17.5-34 Nm (13-25 ft lb) Booster-to-Brake Pedal and Bracket Assembly .............................................................................................................................. 17.5-34 Nm (13-25 ft lb) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5613 Vacuum Brake Booster: Diagrams Brake booster vacuum routing Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5614 Vacuum Brake Booster: Application and ID Part Number ........................................................................................................................................ ........................................................................... 2005 Type ..................................................................................................................................................... ........................................................ Dual Diaphragm Make .................................................................................................................................................... ....................................................................... Bendix O/S Diameter ....................................................................................................................................... ..................................................... 277 mm (10.92 in) Effective Diameter ............................................................................................................................... ..................................................... 342 mm (13.46 in) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Vacuum Brake Booster: Initial Inspection and Diagnostic Overview VISUAL CHECKS Inspect all hoses and connections. All unused vacuum connectors should be capped. Hoses and their connections should be properly secured and in good condition with no holes or collapsed areas. OPERATIONAL CHECKS 1. Check hydraulic brake system for leaks or insufficient fluid. 2. With transmission (7003) in NEUTRAL, stop engine (6007) and apply parking brake control (2780). Apply brake pedal (2455) several times to exhaust all vacuum in the system. 3. Apply brake pedal and hold it in the applied position. Start engine. If vacuum system is operating, brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the power brake booster system is not functioning. Perform a Booster functional test. FUNCTIONAL CHECKS 1. Remove vacuum booster hose from power brake booster and check valve connection. Manifold vacuum should be available at the check valve end of the vacuum booster hose with engine at idle speed and transmission in NEUTRAL. If manifold vacuum is available to the power brake booster, connect vacuum booster hose to power brake booster. 2. With transmission (7003) in NEUTRAL, stop engine (6007) and apply parking brake control (2780). Apply brake pedal (2455) several times to exhaust all vacuum in the system. 3. Apply brake pedal and hold it in the applied position. Start engine. If vacuum system is operating, brake pedal will tend to move downward under constant foot pressure. If no motion is felt, replace the vacuum booster. 4. Operate engine a minimum of 10 seconds at fast idle. Stop engine, and let vehicle stand for 10 minutes. Then, apply brake pedal with approximately 89 N (20 lbs) of force. Brake pedal feel should be the same as that noted with engine operating. If brake pedal feels hard (no power assist), replace check valve and retest. If brake pedal feels spongy, bleed hydraulic system to remove air. Refer to Brake Bleeding. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 5617 Vacuum Brake Booster: Adjustments NOTE: The push rod has an adjustment screw to maintain the correct relationship between the booster control valve plunger and the master cylinder piston. ^ If the plunger is too long, it will prevent the master cylinder piston from completely releasing hydraulic pressure, causing the brakes to drag. ^ If the plunger is too short, it will cause excessive pedal travel and an undesirable clunk in the booster area. Remove the brake master cylinder for access to the booster push rod. Brake Push Rod Adjustment 1. Fabricate a gauge and place it against the master cylinder mounting surface of the booster body as shown. 2. Adjust the push rod screw by turning it until the end of the screw just touches the inner edge of the slot in the gauge. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 5618 Vacuum Brake Booster: Service and Repair Brake Power Booster ITEM PART DESCRIPTION NUMBER 1 2005 Power Brake Booster 2 -- Valve Plunger (Part of 2005) 3 -- Valve Operating Rod (Part of 2005) 4 -- Rubber Reaction Disc (In Position) (Part of 2005) 5 -- Master Cylinder Push Rod (Part of 2005) 6 -- Front Seal (Part of 2005) CAUTION: Make sure the booster rubber reaction disc is properly installed as shown in the above illustration. If the master cylinder push rod is removed or accidentally pulled out, it may dislodge the rubber reaction disc from its seat in the booster. Symptoms of a dislodged disc are excessive pedal travel and extreme power brake sensitivity. If the master cylinder push rod is removed, remove the booster front seal and look into the booster to where the push rod seats. The disc is black rubber. If the disc is dislodged, a silver colored plunger will be exposed. If the rubber reaction disc cannot be located, installed and aligned, then the booster unit must be replaced. NOTE: If power brake booster is damaged or inoperative, replace it with a new booster. The power brake booster is serviced only as an assembly, including the check valve. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 5619 ITEM PART DESCRIPTION NUMBER 1 2450 Brake Pedal and Bracket 2 2005 Power Brake Booster 3 382802-S2 Nut 3/8-16 17.5-34 Nm (13-25 ft lb) 4 56740-S2 Bolt 3/8-16 x 1 Hex Flange 30-41 Nm (22-30 ft lb) 5 2C156 Brake Master Cylinder 6 382802-S2 Nut 3/8-16 17.5-34 Nm (13-25 ft lb) 7 2A309 Brake Master Cylinder Push Rod Bushing 8 2B129 Brake Master Cylinder Push Rod Spacer 9 380699-S100 Pin 10 13480 Stoplight Switch 11 022A68 Cowl, Top (Reference) 12 2365 Valve, Vacuum Check REMOVAL 1. Disconnect the stop lamp switch wiring to prevent running the battery down. 2. Support the brake master cylinder (2140) from the underside with a prop. 3. Loosen the clamp that secures the vacuum booster hose (2A047) to the power brake booster check valve (2365), and remove the vacuum booster hose. Remove the power brake booster check valve. 4. Remove the wrap-around clip (securing brake lines) from booster inboard stud. 5. Remove the master cylinder-to-booster retaining nuts. 6. Pull the brake master cylinder off the power brake booster and leave it supported by the prop, far enough away to allow removal of the power brake booster. 7. From inside the cab, remove the cotter pin and slide the stoplight switch (13480), brake master cylinder push rod spacers (2B129) and brake master cylinder push rod bushing (2A309) off the brake pedal arm. 8. From inside the cab, remove the nuts retaining the power brake booster to the dash. Remove the power brake booster from the engine compartment. NOTE: Make certain that the booster push rod is positioned on the correct side of the brake pedal (2455) to install onto the push pin prior to tightening the power brake booster to the dash. INSTALLATION 1. Mount the power brake booster on the engine side of the dash panel by sliding the bracket mounting bolts and valve operating rod in through the holes in the dash. 2. Install the booster mounting bracket-to-dash panel retaining nuts from inside the cab. Tighten nuts to 18-34 Nm (13-25 ft lb). 3. Position the brake master cylinder on the power brake booster, install the retaining nuts, and remove the prop from underneath the brake master cylinder. Tighten nuts to 18-34 Nm (13-25 ft lb). 4. Install the power brake booster check valve. Connect the vacuum booster hose to the power brake booster check valve and secure with the clamp. Make sure the vacuum booster hose is routed as shown. 5. Install the bushing and position the stoplight switch on the end of the push rod from inside the cab. Then install the stoplight switch and rod on the pedal pin, along with brake master cylinder push rod spacers on each side, and secure with the cotter pin. 6. Connect the stoplamp switch wiring. 7. Start the engine (6007) and check brake operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation Vacuum Brake Booster Check Valve: Description and Operation PURPOSE The function of the power brake booster check valve is to allow manifold vacuum to enter the power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation > Page 5623 Vacuum Brake Booster Check Valve: Testing and Inspection NOTE: This test should only be performed after the brake booster and its vacuum system has been checked and found to be functioning properly. See: Vacuum Brake Booster/Testing and Inspection/Initial Inspection and Diagnostic Overview 1. To test the functioning of the power brake booster check valve: a. Start and run the engine for at least 10 seconds. b. Operate the brake pedal to check for power assist. c. Disconnect the vacuum booster hose from the power brake booster. d. There should be enough vacuum retained in the power brake booster for at least one more power-assisted brake operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Diagrams Vacuum Hose Routing Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Diagrams > Page 5627 Vacuum Pump: Description and Operation Vacuum Hose Routing On diesel engine vehicles, vacuum is supplied from a vacuum pump located on the top left side of the engine. The vacuum pump is driven by a drive belt which drives all accessories. Diesel-engine equipped vehicles employ the use of a distributor modulator valve switch or low vacuum indicator switch. The distributor modulator valve switch is mounted to the left side fender panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Testing and Inspection > A-1 Condition Isolation Vacuum Pump: Testing and Inspection A-1 Condition Isolation ^ Block the wheels and apply the parking brake. ^ Place the transmission in PARK or NEUTRAL. ^ Key ON engine running. ^ Disconnect the low-vacuum switch. Run engine at normal idle speed. Apply brakes. ^ Does brake warning light illuminate? YES -- Condition related to the brake hydraulic system. NO -- Condition related to the vacuum pump. Go to A2. See: A-2 Vacuum Pump Output Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Testing and Inspection > A-1 Condition Isolation > Page 5630 Vacuum Pump: Testing and Inspection A-2 Vacuum Pump Output Vacuum VS Altitude Chart ^ Disconnect the vacuum pump hose from the brake booster and insert a vacuum gauge. Rotunda Model 059-00008 or equivalent, in the hose end. Run the engine at normal curb idle and check vacuum. Gauge should read 70kPa (21 inches Hg) at sea level within 30 seconds (refer to graph for vacuum at other elevations). ^ Is vacuum at or above specified level? YES -- Go to A4. See: A-4 Vacuum System Check NO -- Go to A3. See: A-3 System Integrity Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Testing and Inspection > A-1 Condition Isolation > Page 5631 Vacuum Pump: Testing and Inspection A-3 System Integrity ^ Check gauge and connections for leaks. ^ Check pully fit-to-shaft. ^ Check that engine curbe idle rpm is at specifications. ^ Repeat procedure in step A2, vacuum pump output test. See: A-2 Vacuum Pump Output ^ Is vacuum at or above specified level? YES -- Go to A4. See: A-4 Vacuum System Check NO -- Replace vacuum pump. See: Service and Repair Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Testing and Inspection > A-1 Condition Isolation > Page 5632 Vacuum Pump: Testing and Inspection A-4 Vacuum System Check ^ Reconnect the vacum gauge hose with a T-fitting and connect vacuum gauge so gauge is located near pump inlet. ^ Run engine at curb idle speed. The maximum allowable vacuum drop to be 10kPa (3 inches hg) from the specified level of vacuum described in step A2, vacuum pump outlet Test. See: A-2 Vacuum Pump Output Vacuum Check ^ Is vacuum at or above specified level? YES -- Go to A5. See: A-5 Brake Booster Check NO -- Go to A6. See: A-6 Leak Check Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Testing and Inspection > A-1 Condition Isolation > Page 5633 Vacuum Pump: Testing and Inspection A-1 Condition Isolation ^ Block the wheels and apply the parking brake. ^ Place the transmission in PARK or NEUTRAL. ^ Key ON engine running. ^ Disconnect the low-vacuum switch. Run engine at normal idle speed. Apply brakes. ^ Does brake warning light illuminate? YES -- Condition related to the brake hydraulic system. NO -- Condition related to the vacuum pump. Go to A2. See: A-2 Vacuum Pump Output A-2 Vacuum Pump Output Vacuum VS Altitude Chart ^ Disconnect the vacuum pump hose from the brake booster and insert a vacuum gauge. Rotunda Model 059-00008 or equivalent, in the hose end. Run the engine at normal curb idle and check vacuum. Gauge should read 70kPa (21 inches Hg) at sea level within 30 seconds (refer to graph for vacuum at other elevations). ^ Is vacuum at or above specified level? YES -- Go to A4. See: A-4 Vacuum System Check NO -- Go to A3. See: A-3 System Integrity A-3 System Integrity ^ Check gauge and connections for leaks. ^ Check pully fit-to-shaft. ^ Check that engine curbe idle rpm is at specifications. ^ Repeat procedure in step A2, vacuum pump output test. See: A-2 Vacuum Pump Output ^ Is vacuum at or above specified level? YES -- Go to A4. See: A-4 Vacuum System Check NO -- Replace vacuum pump. See: Service and Repair A-4 Vacuum System Check ^ Reconnect the vacum gauge hose with a T-fitting and connect vacuum gauge so gauge is located near pump inlet. ^ Run engine at curb idle speed. The maximum allowable vacuum drop to be 10kPa (3 inches hg) from the specified level of vacuum described in step A2, vacuum pump outlet Test. See: A-2 Vacuum Pump Output Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Testing and Inspection > A-1 Condition Isolation > Page 5634 Vacuum Check ^ Is vacuum at or above specified level? YES -- Go to A5. See: A-5 Brake Booster Check NO -- Go to A6. See: A-6 Leak Check A-5 Brake Booster Check ^ Depress brake pedal and hold. ^ Repeat step A4, vacuum system check. See: A-4 Vacuum System Check ^ Is vacuum 10kPa (3 inches hg) or above? YES -- Check hydraulic system. NO -- Replace brake booster. A-6 Leak Check ^ Check all attaching hoses for leaks. ^ Is there a leak? YES -- Service as required. NO -- If vacuum is still low, check all vacuum accessories for out-of-specification leaks. Repair or replace as required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Testing and Inspection > Page 5635 Vacuum Pump: Service and Repair REMOVAL 1. Remove air cleaner. 2. Remove drive belt (8620). 3. Partially drain engine coolant. 4. Remove upper radiator hose clamps and upper radiator hose (8260). 5. Disconnect coolant reservoir hose at radiator and support. 6. Remove fan blade (8600) and fan clutch (8A616) using Fan Clutch Nut Wrench T83T-6312-B and Fan Clutch Pulley Holder T94T-6312-AH, set fan blade and fan clutch in fan shroud (8146). Fan Clutch Removal 7. Remove two fan shroud screws. 8. Remove fan shroud and fan blade and fan clutch. 9. Remove vacuum pump pulley using Steering Pump Pulley Remover T69L-10300-B. 10. Remove vacuum pump bolts. 11. Disconnect vacuum pump hose and remove vacuum pump (2A451). INSTALLATION 1. Connect vacuum pump hoses and install vacuum pump. 2. Install vacuum pump bolts. Tighten bolts to 24-31 N-m (18-23 lb-ft). 3. Install vacuum pump pulley using Steering Pump Pulley Replacer T65P-3A733-C. 4. Position the fan shroud, fan blade and fan clutch. 5. Install fan shroud screws. 6. Install fan blade and fan clutch using Fan Clutch Nut Wrench T83T-6312-B and Fan Clutch Pulley Holder T94T-6312-AH. 7. Connect coolant reservoir hose at radiator and support. 8. Install upper radiator hose and hose clamps. 9. Refill engine coolant. 10. Install drive belt. 11. Install air cleaner assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Testing and Inspection > Page 5636 Vacuum Pump Installation View Item Part Number Description 1 N605790-S2 Bolt, Vacuum 2 2A451 Vacuum Pump 3 3A674 Power Steering Pump 4 26487 Vacuum Pump Pulley A -- Tighten to 24-31 Nm (18-23 ft lb) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Testing and Inspection > Page 5637 Vacuum Pump: Tools and Equipment Steering Pump Pulley Replacer Steering Pump Pulley Replacer Steering Pump Pulley Remover Steering Pump Pulley Remover Fan Clutch Nut Wrench Fan Clutch Nut Wrench Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump Switch, Brakes > Component Information > Locations Vacuum Hose Routing Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump Switch, Brakes > Component Information > Locations > Page 5641 Vacuum Pump Switch: Service and Repair Vacuum Hose Routing NOTE: The distributor modulator valve (low vacuum) switch is mounted to the left side fender panel. REMOVAL 1. Remove the negative battery cable from both batteries. 2. Disconnect vacuum hose and the electrical cable from distributor modulator valve switch. 3. Remove two attaching nuts and remove distributor modulator valve switch and A/C compressor mounting bracket (2882). INSTALLATION 1. Reverse the above procedure for installation, Tighten nuts to 8-11 Nm (6-8 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Service and Repair ABS Main Relay: Service and Repair REMOVAL and INSTALLATION 1. Open power distribution box. 2. Locate relay in power distribution box. 3. Pull relay from ABS relay socket. 4. For installation, follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Anti-Lock Brake System Module: > 98-5A-42 > Mar > 98 > ABS System - 4WABS Lamp On/False ABS Codes In Memory Anti-Lock Brake System Module: Customer Interest ABS System - 4WABS Lamp On/False ABS Codes In Memory Article No. 98-5A-42 03/18/98 ^ BRAKES - 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) - ABS LAMP ILLUMINATED FALSE ABS CODES IN MEMORY - VEHICLES BUILT THROUGH 2/23/96 ^ LAMP - ANTI-LOCK BRAKE SYSTEM (ABS) LAMP ILLUMINATED - FALSE ABS CODES IN MEMORY - VEHICLES BUILT THROUGH 2/23/96 WITH 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) LIGHT TRUCK: 1994-96 ECONOLINE ISSUE: The Anti-lock Brake System (ABS) lamp remains on after the vehicle is started and six (6) ABS codes are stored in memory on some vehicles. This may be due to the programming in the 4WABS module. ACTION: Replace the 4WABS module with a revised module. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm the vehicle has all of the following ABS codes in memory: NOTE: NO MORE, OR LESS, OF THE FOLLOWING CODES MUST BE PRESENT FOR THIS CONCERN. ^ B1342 - ABS Electronic Control Module (ECU) failure ^ C1222 - Wheel speed mismatch ^ C1115 - Power relay output short circuit to battery ^ C1184 - System timeout ^ C1220 - Warning lamp output short circuit to battery ^ C1226 - Brake warning lamp output short circuit to ground 2. If all six (6) codes are present, refer to the 1995 Econoline Service Manual, Pages 06-09B-106 and 06-09B-107 in order to replace the ABS module. Refer to the Application Chart for correct ABS module replacement. PART NUMBER PART NAME F6UZ-2B373-BA ABS Module F6UZ-2B373-CA ABS Module F6UZ-2B373-EA ABS Module OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-7-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Anti-Lock Brake System Module: > 98-5A-42 > Mar > 98 > ABS System - 4WABS Lamp On/False ABS Codes In Memory > Page 5654 OPERATION DESCRIPTION TIME 985A42A Perform Diagnosis And 0.8 Hr. Replace Anti-Lock Brake System Module DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 OASIS CODES: 206000, 301000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Anti-Lock Brake System Module: > 98-5A-42 > Mar > 98 > ABS System - 4WABS Lamp On/False ABS Codes In Memory Anti-Lock Brake System Module: All Technical Service Bulletins ABS System - 4WABS Lamp On/False ABS Codes In Memory Article No. 98-5A-42 03/18/98 ^ BRAKES - 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) - ABS LAMP ILLUMINATED FALSE ABS CODES IN MEMORY - VEHICLES BUILT THROUGH 2/23/96 ^ LAMP - ANTI-LOCK BRAKE SYSTEM (ABS) LAMP ILLUMINATED - FALSE ABS CODES IN MEMORY - VEHICLES BUILT THROUGH 2/23/96 WITH 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) LIGHT TRUCK: 1994-96 ECONOLINE ISSUE: The Anti-lock Brake System (ABS) lamp remains on after the vehicle is started and six (6) ABS codes are stored in memory on some vehicles. This may be due to the programming in the 4WABS module. ACTION: Replace the 4WABS module with a revised module. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm the vehicle has all of the following ABS codes in memory: NOTE: NO MORE, OR LESS, OF THE FOLLOWING CODES MUST BE PRESENT FOR THIS CONCERN. ^ B1342 - ABS Electronic Control Module (ECU) failure ^ C1222 - Wheel speed mismatch ^ C1115 - Power relay output short circuit to battery ^ C1184 - System timeout ^ C1220 - Warning lamp output short circuit to battery ^ C1226 - Brake warning lamp output short circuit to ground 2. If all six (6) codes are present, refer to the 1995 Econoline Service Manual, Pages 06-09B-106 and 06-09B-107 in order to replace the ABS module. Refer to the Application Chart for correct ABS module replacement. PART NUMBER PART NAME F6UZ-2B373-BA ABS Module F6UZ-2B373-CA ABS Module F6UZ-2B373-EA ABS Module OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-7-21 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Anti-Lock Brake System Module: > 98-5A-42 > Mar > 98 > ABS System - 4WABS Lamp On/False ABS Codes In Memory > Page 5660 OPERATION DESCRIPTION TIME 985A42A Perform Diagnosis And 0.8 Hr. Replace Anti-Lock Brake System Module DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 OASIS CODES: 206000, 301000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 5661 Anti-Lock Brake System Module: Locations Full Body View (Part 2 Of 2) The 4 Wheel Anti-Lock Brakes Module is located on the LH front frame rail. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Diagrams > Four Wheel Antilock Brakes 4 Wheel Anti-Lock Brakes System Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Diagrams > Four Wheel Antilock Brakes > Page 5664 Rear Anti-Lock Brake System Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Description and Operation > Four Wheel Anti-Lock Brake System (4WABS) Anti-Lock Brake System Module: Description and Operation Four Wheel Anti-Lock Brake System (4WABS) PURPOSE The antilock brake electronic control module monitors the brake on/off switch and the system speed sensors to determine when the antilock brake system should be engaged. In addition, the electronic control module provides a speed signal to the Programmable Speedometer/Odometer Module (PSOM). DESCRIPTION It is an on-board diagnostic, non-repairable unit consisting of two microprocessors and necessary circuitry for their operation. These microprocessors are programmed identically. The antilock brake electronic control module monitors system operation during normal driving as well as during antilock braking. OPERATION Under normal driving conditions, the microprocessors produce short test pulses to check the electrical system without any mechanical reaction. The antilock brake electronic control module continuously monitors the speed of each wheel to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the antilock brake electronic control module signals the appropriate solenoid valve in the antilock hydraulic control unit to open or close as well as the pump motor to turn on and recycle brake fluid back to the brake master cylinder. This results in moderate pulsations of the brake pedal and pump noise which may be heard in the passenger compartment. During normal braking, the brake pedal feel will be identical to a standard brake system. Most concerns which occur to the antilock brake system will be stored as a coded number in the Keep-Alive Memory (KAM) of the antilock brake electronic control module. This means that once a code is stored, it will be retained by the antilock brake electronic control module even with the key in the OFF position. The codes can be retrieved by following the on-board diagnostic procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Description and Operation > Four Wheel Anti-Lock Brake System (4WABS) > Page 5667 Anti-Lock Brake System Module: Description and Operation Rear Anti-Lock Brake System (RABS) PURPOSE The Rear Antilock Brake System (RABS) module continuously monitors the rear wheel speed with a sensor mounted on the rear axle for an impending rear wheel lockup condition during braking. The RABS Module will modulate hydraulic pressure to the rear brake cylinders to inhibit rear wheel lockup. The RABS Module has self-test capabilities much like those in other electronic control systems. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) Anti-Lock Brake System Module: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) REMOVAL 1. Disconnect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Locate antilock brake control module on ABS bracket, the bracket is located in the front left hand frame inboard liner just under the driver's seat. Disconnect 40-pin connector from antilock brake control module. 3. Remove screws retaining antilock brake control module to mounting bracket. 4. Gently slide antilock brake control module along bracket and remove antilock brake control module. INSTALLATION 1. Insert antilock brake control module into mounting bracket and install retaining screws (4). Tighten to 7-9 Nm (62-80 lb ft). 2. Install retaining screw and tighten to 7-9 Nm (62-80 lb ft). 3. Connect 40-pin connector and tighten bolt to 6-7 Nm (53-62 lb ft). 4. Connect negative battery cable. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Anti-Lock Brake System Module <--> [Electronic Brake Control Module] > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 5670 Anti-Lock Brake System Module: Service and Repair Rear Antilock Brake System (RABS) REMOVAL AND INSTALLATION Anti-Lock Electronic Control Unit 1. Remove the screws/washers that hold the antilock electronic control module to the instrument panel lower brace. Pull the antilock electronic control module off the retainer clip assembly. 2. Disconnect the wiring harness from the antilock electronic control module by depressing the plastic tab on the connector and pulling the connector off. 3. For installation, follow removal steps in reverse order, followed by a system check for proper operation. Tighten screws/washers to 2 Nm (18 lb in) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Description and Operation Acceleration/Deceleration Sensor: Description and Operation PURPOSE This G-Switch is used to determine the vehicle's deceleration rate. OPERATION A component that is unique to the Ford light truck 4-Wheel ABS is the G-Switch, located where the Rear ABS valve used to be. The deceleration rate information, combined with signals from the wheel speed sensors, is used by the ECU to adjust ABS function to different operating conditions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Fluid Level Sensor, ABS Brake Fluid Level Sensor/Switch: Description and Operation Fluid Level Sensor, ABS Master Cylinder Reservoir PURPOSE The Master Cylinder Reservoir with Low Fluid Level Warning Switch monitors the fluid level in the master cylinder. OPERATION When a low fluid level condition occurs, a path to ground is provided through the dual brake warning switch to disable the Antilock brake system and illuminate the Antilock brake indicator. CONSTRUCTION The low fluid level warning switch is an integral part of the brake master cylinder reservoir. It is serviced as a part of the brake master cylinder reservoir. It consists of a float and magnet assembly and a reed switch. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Fluid Level Sensor, ABS > Page 5679 Brake Fluid Level Sensor/Switch: Description and Operation Fluid Level Sensor, Brakes PURPOSE The brake fluid level switch closes with low brake fluid level. When closed, a ground is applied to the brake indicator and the lamp will illuminate. NOTE: The brake fluid level sensor is part of the master cylinder reservoir and is not serviced separately. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 5680 Brake Fluid Level Sensor/Switch: Service and Repair The brake master cylinder sensor is part of the brake master cylinder reservoir and is not separately serviceable. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Service and Repair Braking Sensor/Switch: Service and Repair REMOVAL 1. Disconnect wiring harness connector from stoplight switch. 2. Remove self-locking pin and spacer from brake pedal pin. 3. Slide brake booster rod and stoplight switch off brake pedal pin. 4. Remove stoplight switch and bushing from brake booster rod. INSTALLATION 1. Position bushing in stoplight switch. 2. Position stoplight switch on brake booster rod, aligning holes. 3. Slide brake booster rod and stoplight switch onto brake pedal pin. 4. Install spacer and self-locking pin on brake pedal pin. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Vacuum Pump Switch, Brakes > Component Information > Locations Vacuum Hose Routing Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Vacuum Pump Switch, Brakes > Component Information > Locations > Page 5687 Vacuum Pump Switch: Service and Repair Vacuum Hose Routing NOTE: The distributor modulator valve (low vacuum) switch is mounted to the left side fender panel. REMOVAL 1. Remove the negative battery cable from both batteries. 2. Disconnect vacuum hose and the electrical cable from distributor modulator valve switch. 3. Remove two attaching nuts and remove distributor modulator valve switch and A/C compressor mounting bracket (2882). INSTALLATION 1. Reverse the above procedure for installation, Tighten nuts to 8-11 Nm (6-8 ft lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > ABS - Wheel Speed Sensors Are Not Interchangeable Wheel Speed Sensor: Technical Service Bulletins ABS - Wheel Speed Sensors Are Not Interchangeable Article No. 98-5A-43 03/18/98 BRAKES - ANTI-LOCK BRAKE SYSTEM (ABS) - WHEEL SPEED SENSORS ARE NOT INTERCHANGEABLE LIGHT TRUCK: 1994-95 ECONOLINE ISSUE: The Anti-lock Brake System (ABS) wheel sensors are not interchangeable for 1994-95 Econolines. ACTION: If replacing an ABS wheel sensor, refer to the Econoline Wheel Speed Sensor Application Chart for proper wheel sensor usage. CAUTION: USING THE WRONG WHEEL SENSOR WILL NOT GIVE YOU ANY ERROR CODES, BUT THE WIRES WILL BE MISROUTED. THIS MAY EVENTUALLY CAUSE THE SENSOR WIRE TO CONTACT THE TIRE/WHEEL AND POTENTIALLY RUB THROUGH. PART NUMBER PART NAME F4UZ-2C204-C ABS Wheel Speed Sensor F4UZ-2C204-D ABS Wheel Speed Sensor F6UZ-2C204-AA ABS Wheel Speed Sensor F6UZ-2C204-AB ABS Wheel Speed Sensor OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-13-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensor: Locations Front The front brake antilock sensors are attached to the suspension knuckles, and the front brake antilock sensor indicators are pressed onto the backside of the rotor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front > Page 5694 Wheel Speed Sensor: Locations Rear The Vehicle Speed Sensor (VSS) is located on the axle assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 5695 Wheel Speed Sensor: Description and Operation PURPOSE A variable reluctance sensor and toothed speed indicator ring used to determine wheel speed. OPERATION As the ring teeth pass by the reluctance sensor, a pulsing voltage signal is generated and sent to the antilock brake system control module. Voltage pulses are directly proportional to rotational wheel speed. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Front REMOVAL 1. Raise vehicle on hoist. 2. Remove wheel and tire assembly. Rotor And Speed Sensor Ring 3. Remove caliper, rotor and hub assemblies. Speed Sensor Ring Removal 4. Using a 3-jaw puller, D80L-1013-A or equivalent, remove speed sensor ring from hub. CAUTION: Discard old speed sensor ring after removal. Do not reuse. INSTALLATION 1. Support center of hub so that wheel studs do not rest on work surface. CAUTION: When performing the following step, make sure indicator ring is pressed on straight. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5698 Front Speed Sensor Ring Installation 2. Position new speed sensor ring on hub. Using a cylinder with 98mm (3.9 inch) ID and 106mm (4.2 inch) OD, press the ring on to the hub. The ring must be fully seated against the shoulder in the hub. 3. Install hub, rotor and caliper assemblies. 4. Install wheel and tire assembly. Tighten wheel lugnuts to 115-142 Nm (85-105 ft lb). Rear INSPECTION 1. Remove the sensor. 2. View the speed sensor ring teeth through the sensor hole. Rotate the rear axle and check the speed sensor ring teeth for damage or breakage. Dented or broken teeth could cause the ABS system to function when not required. REMOVAL To service the speed sensor ring, the differential case must be removed from the axle housing, and the speed sensor ring pressed off the case. Upon removal, the speed sensor ring is to be discarded. It is not to be reused. Rear Antilock Brake System (RABS) INSPECTION 1. Remove the sensor. 2. View the speed sensor ring teeth through the sensor hole. Rotate the rear axle and check the speed sensor ring teeth for damage or breakage. Dented or broken teeth could cause the ABS system to function when not required. REMOVAL To service the speed sensor ring, the differential case must be removed from the axle housing, and the speed sensor ring pressed off the case. Upon removal, the speed sensor ring is to be discarded. It is not to be reused. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5699 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Rear Antilock Brake System Rear Speed Sensor REMOVAL 1. At the rear axle housing pull the wiring harness connector from the speed sensor. 2. Remove the speed sensor hold down bolt and remove the speed sensor from the rear axle housing. INSTALLATION 1. Clean the rear axle housing mounting surface. Use care to prevent dirt from entering the rear axle housing. 2. Inspect and clean the magnetized sensor pole piece to make sure that it is free from loose metal particles which could cause erratic system operation. Inspect the speed sensor O-ring for damage and replace if necessary. 3. Lightly lubricate the speed sensor O-ring with motor oil, align the bolt hole, and install. NOTE: Do not apply force to the plastic sensor connector. The sensor flange should slide to the mounting surface. This will make sure the air gap setting is between 0.127-1.143mm (0.005-0.045 in). 4. Install the speed sensor hold-down bolt and tighten to 34-40 Nm (25-29 ft lb). 5. Push the connector on the speed sensor. Front REMOVAL and INSTALLATION 1. From frame rail, disconnect sensor assembly two-pin connector from wiring harness. 2. Separate sensor cable from brake hose clips. 3. Remove sensor out of mating hole. 5. Remove the rotor. 5. For installation, follow removal procedures in reverse order. Tighten retaining bolt to 5-6 Nm (44-53 in lb). Rear REMOVAL Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5700 1. Pull the wiring harness connector from the sensor. 2. Remove the sensor hold down bolt and remove the sensor from the axle housing. INSTALLATION 1. Clean the axle mounting surface. Use care to prevent dirt from entering the axle housing. 2. Inspect and clean the magnetized sensor pole piece to make sure that it is free from loose metal particles which could cause erratic system operation. Replace the sensor O-ring. 3. Lightly lubricate the sensor O-ring with motor oil, align the sensor bolt hole, and install. Do not apply force to the plastic sensor connector. The sensor flange should slide to the mounting surface. This will make sure the air gap setting is between 0.127-1.14mm (0.005-0.045 in). 4. Install the hold down bolt and tighten to 34-40 Nm (25-30 ft lb). 5. Push the electrical connector on the sensor. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams Ignition Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 5706 Ignition Switch: Testing and Inspection Ignition Switch - Component Testing Procedure (Part 1 Of 2) Ignition Switch - Component Testing Procedure (Part 2 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 5707 Ignition Switch - Terminal Locations Ignition Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > With E4OD Transmission Neutral Safety Switch: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > With E4OD Transmission > Page 5712 Neutral Safety Switch: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Park/Neutral Position Switch Park/Neutral Position Switch (With C6 Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Park/Neutral Position Switch > Page 5715 Neutral Safety Switch: Diagrams Transmission Range Sensor Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Park/Neutral Position Switch > Page 5716 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Testing and Inspection > With E4OD Transmission Neutral Safety Switch: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Testing and Inspection > With E4OD Transmission > Page 5719 Neutral Safety Switch: Testing and Inspection With 4R70W Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > E4OD Transmission Neutral Safety Switch: Service and Repair E4OD Transmission REMOVAL AND INSTALLATION 1. Apply parking brake, then place gear selector lever in Neutral position. 2. Ensure transmission shift cable is correctly adjusted, then loosen Park/Neutral position switch retaining bolts. 3. Insert Gear Position Sensor Adjuster tool No. T92P-70010-AH, or equivalent, on Park/Neutral position switch into the three slots provided on the switch actuator and terminal plate. 4. Leaving the alignment tool in place, torque switch retaining bolts to 6 ft lb. 5. Remove alignment tool, adjustment can be verified visually by making sure the line etched in the housing are in a straight line when the Park/Neutral position switch is centered in neutral. 6. Check the operation of the Park/Neutral position switch. The back-up lamps should operate only with the transmission selector lever in reverse. The vehicle should only start with the selector lever in park or neutral. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair > E4OD Transmission > Page 5722 Neutral Safety Switch: Service and Repair C-6 Transmission REMOVAL AND INSTALLATION 1. Apply parking brake, then place gear selector lever in Neutral position. 2. Ensure transmission shift cable is correctly adjusted, then loosen Park/Neutral position switch retaining bolts. 3. Insert Gear Position Sensor Adjuster tool No. T91P-70010-A, or equivalent, on Park/Neutral position switch into the three slots provided on the switch actuator and terminal plate. 4. Leaving the alignment tool in place, torque switch retaining bolts to 6 ft lb. 5. Remove alignment tool, adjustment can be verified visually by making sure the line etched in the housing are in a straight line when the Park/Neutral position switch is centered in neutral. 6. Check the operation of the Park/Neutral position switch. The back-up lamps should operate only with the transmission selector lever in reverse. The vehicle should only start with the selector lever in park or neutral. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Motor Relay <--> [Starter Relay] > Component Information > Locations Starter Motor Relay: Locations Engine Compartment View The Starter Motor Relay is located at the LH front corner of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications Generator: Electrical Specifications Alternator With Current Rating of: 95 Amperes: Volts ..................................................................................................................................................... .................................................................... 15.0 Alternator With Current Rating of 130 Amperes: Volts ..................................................................................................................................................... ....................................................................... -- Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications > Page 5732 Generator: Mechanical Specifications Alternator With Current Rating of: 95. Regulator ............................................................................................................................................. ................................................................ Internal Slip Ring Turning Minimum Diameter .............................................................................................................................. ........................................................ 1.04 Inch Maximum Runout ........................................................ ............................................................................................................................. 0.0005 Inch Brush Length New ..................................................................................................................................................... ....................................................... 0.709 Inch Wear Limit .................................................................. ................................................................................................................................. 0.12 Inch Alternator With Current Rating of: 130 Regulator ............................................................................................................................................. ................................................................ Internal Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Rectifier Short or Grounded and Stator Grounded Test Generator: Testing and Inspection Rectifier Short or Grounded and Stator Grounded Test Diode Trio Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Rectifier Short or Grounded and Stator Grounded Test > Page 5735 Alternator W/Integral Regulator Rectifier Short Or Grounded & Stator Grounded Test 1. Using a suitable ohmmeter, connect one probe to alternator BAT (B+) terminal 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. 2. 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 proceeding tests indicates an open STA terminal lead connection inside the alternator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Rectifier Short or Grounded and Stator Grounded Test > Page 5736 Generator: Testing and Inspection Field Open or Short Circuit Test Alternator W/Integral Regulator Field Open Or Short Circuit Test 1. Using a suitable ohmmeter, connect regulator A blade terminal with one probe and the regulator "F" terminal screw head with the other probe. 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, faulty 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 faulty regulator. 5. An ohmmeter reading significantly over 9 ohms in both directions indicates a faulty 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. 7. If ohmmeter reads less than infinite at either point, a grounded brush lead, grounded rotor or faulty regulator is indicated. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Page 5737 Generator: Service and Repair 1. Disconnect battery ground cable. 2. Remove air cleaner assembly, if necessary. 3. Disconnect wire harness connectors from voltage regulator. 4. Remove accessory drive belt. 5. Remove two alternator mounting bolts, then the alternator. 6. Remove alternator fan shield, if equipped. 7. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: Customer Interest Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 5747 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 5748 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 5749 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: All Technical Service Bulletins Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 5755 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 5756 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Lock: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 5757 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Lock Cylinder Functional Ignition Lock: Service and Repair Lock Cylinder Functional NOTE: The following procedure applies to vehicle that have functional lock cylinders. Lock cylinder keys are available for these vehicles, or the lock cylinder key numbers are known and the proper key can be made. Removal 1. Disarm Airbag. Disconnect battery ground cable. 2. Turn lock cylinder key to RUN position. Removing Lock Cylinder 3. Place a 3.17 mm (1/8 inch) diameter wire pin or small drift punch in hole in trim shroud under lock cylinder. Depress retaining pin while pulling out on lock cylinder to remove it from column housing. Installation 1. Install lock cylinder by turning it to RUN position and depressing retaining pin. Insert lock cylinder into lock cylinder housing. Make sure cylinder is fully seated and aligned in interlocking washer before turning key to OFF position. This will permit cylinder retaining pin to extend into cylinder housing hole. 2. ROTATE lock cylinder. using lock cylinder key, to ensure correct mechanical operation in all positions. 3. Connect battery ground cable. NOTE: On vehicles equipped with Powertrain Control Module (PCM), when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the PCM processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 4. Rearm Airbag. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Lock Cylinder Functional > Page 5760 Ignition Lock: Service and Repair Lock Cylinder Non-Functional NOTE: The following procedure applies to vehicles in which the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken lock cylinder key, unknown key number, or a lock cylinder cap that has been damaged and I or broken to the extent that the lock cylinder cannot be rotated. Removal 1. Disarm Airbag. Disconnect battery ground cable. 2. Remove steering wheel. Refer to Steering Wheel: Service and Repair. 3. Using channel lock pliers or vise grip pliers, twist lock cylinder cap until it separates from the lock cylinder. 4. Using a 3/8-inch diameter drill, drill down middle of ignition lock key slot approximately 44 mm (1-3/4 inch) until lock cylinder breaks loose from breakaway base of lock cylinder. Remove lock cylinder and drill shavings from lock cylinder housing. 5. Remove retainer, washer, ignition switch and actuator. Thoroughly clean all drill shavings and other foreign materials from casting. 6. Carefully inspect lock cylinder housing for damage from the above operation. If damage is apparent, housing must be replaced. Installation 1. Replace lock cylinder housing, if damaged. 2. Install actuator and ignition switch. 3. Install trim and electrical parts. 4. Install new ignition lock cylinder by turning it to RUN position and depressing retaining pin. Insert lock cylinder into lock cylinder housing. Make sure cylinder is fully seated and aligned in interlocking washer before turning key to OFF position. This will permit cylinder retaining pin to extend into cylinder housing hole. 5. ROTATE lock cylinder. using lock cylinder key, to ensure correct mechanical operation in all positions. 6. Install steering wheel. Refer to Steering Wheel: Service and Repair. 7. Connect battery ground cable. NOTE: On vehicles equipped with Powertrain Control Module (PCM), when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the PCM processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 8. Rearm Airbag. 9. Check lock cylinder operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams Ignition Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Page 5764 Ignition Switch: Testing and Inspection Ignition Switch - Component Testing Procedure (Part 1 Of 2) Ignition Switch - Component Testing Procedure (Part 2 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Page 5765 Ignition Switch - Terminal Locations Ignition Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > With E4OD Transmission Neutral Safety Switch: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > With E4OD Transmission > Page 5770 Neutral Safety Switch: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Park/Neutral Position Switch Park/Neutral Position Switch (With C6 Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Park/Neutral Position Switch > Page 5773 Neutral Safety Switch: Diagrams Transmission Range Sensor Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Park/Neutral Position Switch > Page 5774 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Testing and Inspection > With E4OD Transmission Neutral Safety Switch: Testing and Inspection With E4OD Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Testing and Inspection > With E4OD Transmission > Page 5777 Neutral Safety Switch: Testing and Inspection With 4R70W Transmission Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With 4R70W Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Service and Repair > E4OD Transmission Neutral Safety Switch: Service and Repair E4OD Transmission REMOVAL AND INSTALLATION 1. Apply parking brake, then place gear selector lever in Neutral position. 2. Ensure transmission shift cable is correctly adjusted, then loosen Park/Neutral position switch retaining bolts. 3. Insert Gear Position Sensor Adjuster tool No. T92P-70010-AH, or equivalent, on Park/Neutral position switch into the three slots provided on the switch actuator and terminal plate. 4. Leaving the alignment tool in place, torque switch retaining bolts to 6 ft lb. 5. Remove alignment tool, adjustment can be verified visually by making sure the line etched in the housing are in a straight line when the Park/Neutral position switch is centered in neutral. 6. Check the operation of the Park/Neutral position switch. The back-up lamps should operate only with the transmission selector lever in reverse. The vehicle should only start with the selector lever in park or neutral. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Service and Repair > E4OD Transmission > Page 5780 Neutral Safety Switch: Service and Repair C-6 Transmission REMOVAL AND INSTALLATION 1. Apply parking brake, then place gear selector lever in Neutral position. 2. Ensure transmission shift cable is correctly adjusted, then loosen Park/Neutral position switch retaining bolts. 3. Insert Gear Position Sensor Adjuster tool No. T91P-70010-A, or equivalent, on Park/Neutral position switch into the three slots provided on the switch actuator and terminal plate. 4. Leaving the alignment tool in place, torque switch retaining bolts to 6 ft lb. 5. Remove alignment tool, adjustment can be verified visually by making sure the line etched in the housing are in a straight line when the Park/Neutral position switch is centered in neutral. 6. Check the operation of the Park/Neutral position switch. The back-up lamps should operate only with the transmission selector lever in reverse. The vehicle should only start with the selector lever in park or neutral. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Starter Diameter .................................................................................................................................. ........................................................................ 3 Inch Ampere Draw Normal Load ............................. ........................................................................................................................................................ 130-220 No-Load Ampere @ 12 Volts ................................................................................................ ...................................................................................... 60-80 Starter Diameter .................................................................................................................................. .................................................................. 3 2/5 Inch Ampere Draw Normal Load ............................. ........................................................................................................................................................ 230-630 No-Load Ampere @ 12 Volts ................................................................................................ ......................................................................................... 170 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 5785 Starter Motor: Mechanical Specifications Starter Diameter .................................................................................................................................. ........................................................................ 3 Inch Engine Cranking Speed ................................... ............................................................................................................................................... 100-230 RPM Minimum Stall Torque @ 2.5 Volts ............................................................................................. .......................................................................... 11 Ft Lbs Brushes Length ........................................ .............................................................................................................................................................. . 0.66 Inch Spring Tension ................................................................................................................... .................................................................................. 64 Ounces Starter Diameter .................................................................................................................................. .................................................................. 3 2/5 Inch Engine Cranking Speed ................................... ............................................................................................................................................... 150-200 RPM Minimum Stall Torque @ 2.5 Volts ............................................................................................. ....................................................................... 27.5 Ft Lbs Brushes Length ........................................ .............................................................................................................................................................. . 0.71 Inch Spring Tension ................................................................................................................... ................................................................................ 122 Ounces Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 5786 Starter Motor: Description and Operation MITSUBISHI GEAR REDUCTION STARTERS Exploded View Of Mitsubishi Starter These starters are 12 volt units that have the solenoid mounted on the starter housing. The solenoid is energized when starter relay contacts are closed causing starter drive to engage with flywheel ring gear, thereby starting the engine. An overrunning clutch in the drive protects starter from excessive speeds once engine starts. The current flows through solenoid energizing coil until solenoid plunger is at full travel, at which time plunger closes a set of contacts that bypass the energizing coil, allowing the holding coil to keep starter drive engaged and passing starting current to the starter. The gear reduction starter motor is a compact-type starter that uses an integral starter solenoid. With a gear reduction system, the starter motor is relatively small but still provides the necessary torque to crank the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Starter Motor: Initial Inspection and Diagnostic Overview Armature Open Circuit Inspection 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. Pinion Inspection Pinion Travel Check 1. Using two switches and a battery, connect starter as shown. 2. When switches K1 and K2 are closed the starter drive will be forced outward and the motor will run. If switch K2 is opened, the starter will stop turning with the pinion in the full out position. 3. Check pinion end gap in this position. End gap should be 0.004-0.100 inch. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5789 Starter Motor: Component Tests and General Diagnostics Troubleshooting Charts Troubleshooting Chart Starting System Testing Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5790 Starting System Testing No-Load Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5791 Starter No-load Test Connections 1. Connect starter as shown. 2. Close switch K1 and check starter operation. Starter should operate smoothly. 3. If starter rotates slowly, check clearance between the armature and starter housing. Clearance should be 0.001-0.020 inch. Clearance is determined by the shim behind the bearing in the end cover. Field Grounded Circuit Test 1. Check insulation between yoke and field terminal using circuit tester. Circuit tester should show infinite resistance. 2. Ensure there is continuity between lead wires. Starter Load Test Starter Load Test Connections 1. Connect test equipment as shown, ensuring that there is no current flowing through ammeter and heavy duty carbon pile rheostat portion of circuit. 2. Disconnect push on connectors at starter solenoid and connect remote control starter switch from positive battery cable to S terminal of starter solenoid. 3. Crank engine with remote starter switch and determine exact reading on voltmeter. 4. Stop cranking engine, then reduce resistance of carbon pile until voltmeter indicates same reading as when engine was cranked. Ammeter should read less than 500 amps. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Page 5792 Starter Motor: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect battery ground cable. 2. Raise and support vehicle, if necessary. 3. Disconnect electrical connector or solenoid relay wire from starter motor. 4. Remove starter motor attaching bolts and the starter motor. 5. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor Relay <--> [Starter Relay] > Component Information > Locations Starter Motor Relay: Locations Engine Compartment View The Starter Motor Relay is located at the LH front corner of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 Circuit Breaker: Electrical Diagrams Circuit Breaker 12 For wiring diagrams, please refer to Starting and Charging/Power and Ground Distribution/Diagrams/Electrical/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit Breaker 12. See: Diagrams/Electrical Diagrams/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit Breaker 12 Circuit Breaker 14 For wiring diagrams, please refer to Starting and Charging/Power and Ground Distribution/Diagrams/Electrical/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit Breaker 14. See: Diagrams/Electrical Diagrams/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit Breaker 14 Circuit-To-Circuit Breaker Cross Reference For wiring diagrams, please refer to Starting and Charging/Power and Ground Distribution/Diagrams/Electrical/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit-to-Circuit Breaker Cross Reference. See: Diagrams/Electrical Diagrams/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit-to-Circuit Breaker Cross Reference Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement Article No. 96-24-6 11/18/96 WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350 SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE This TSB article is being republished in its entirety to update the applicable model years. ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved Ford service diode. Some electrical diodes used in early production vehicles are color coded for the purpose of size identification while others are stamped with a manufacture number. All Ford service diodes and current production diodes are identified by manufacture number. ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the following Electrical Diode Application Chart for the correct service part number. NOTE: IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 5813 ELECTRICAL DIODE APPLICATION CHART PART NUMBER PART NAME E8DZ-10C912-A Diode - 1.0 Amp - 400V E8DZ-10C912-B Diode - 6.0 Amp - 400V OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-2-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 2770 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5822 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5823 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5824 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5825 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5826 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5827 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5828 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5829 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5835 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5836 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5837 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5838 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5839 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5840 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5841 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5842 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 961418 > Jul > 96 > Mega Fuse - Vibration Breakage Fuse: Customer Interest Mega Fuse - Vibration Breakage Article No. 96-14-18 07/01/96 MEGA FUSE - VIBRATION CAUSES MEGA FUSE TO OPEN - AMBULANCE CONVERSIONS WITH 7.3L DIT ONLY LIGHT TRUCK: 1995-96 E-350 ISSUE: Ambulance conversion companies modify the electrical distribution system in E-350 vehicles with 7.3L DIT engines. These modifications to the original equipment wiring in the area of the Mega Fuse may decrease the strain relief which results in vibration of the Mega Fuse. This vibration may lead to breakage of the fuse at the point of highest stress. ACTION: Replace the Mega Fuse (Figure 1) with a shunt. The shunt should reduce the possibility of fuse breakage caused by vibration. Refer to the following text for details. Contact the original conversion company to discuss the replacement of the Mega Fuse. If the original conversion company approves of the replacement, remove the Mega Fuse and replace it with a shunt. Torque the Mega Fuse holder to 12-18 N-m (9-13 lb-ft). PART NUMBER PART NAME F6UZ-11A086-AA Shunt OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961418A Install Shunt 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 11A086 X6 OASIS CODES: 203000, 203200, 603300, 607000, 614000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 961418 > Jul > 96 > Mega Fuse - Vibration Breakage Fuse: All Technical Service Bulletins Mega Fuse - Vibration Breakage Article No. 96-14-18 07/01/96 MEGA FUSE - VIBRATION CAUSES MEGA FUSE TO OPEN - AMBULANCE CONVERSIONS WITH 7.3L DIT ONLY LIGHT TRUCK: 1995-96 E-350 ISSUE: Ambulance conversion companies modify the electrical distribution system in E-350 vehicles with 7.3L DIT engines. These modifications to the original equipment wiring in the area of the Mega Fuse may decrease the strain relief which results in vibration of the Mega Fuse. This vibration may lead to breakage of the fuse at the point of highest stress. ACTION: Replace the Mega Fuse (Figure 1) with a shunt. The shunt should reduce the possibility of fuse breakage caused by vibration. Refer to the following text for details. Contact the original conversion company to discuss the replacement of the Mega Fuse. If the original conversion company approves of the replacement, remove the Mega Fuse and replace it with a shunt. Torque the Mega Fuse holder to 12-18 N-m (9-13 lb-ft). PART NUMBER PART NAME F6UZ-11A086-AA Shunt OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961418A Install Shunt 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 11A086 X6 OASIS CODES: 203000, 203200, 603300, 607000, 614000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5858 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5859 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5860 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5861 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5864 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5865 Fuse: Electrical Diagrams Circuit-to-Fuse Cross Reference 4 Wheel Anti-Lock Brakes System Relay ........................................................................................................................................................... Fuse U & V Auxiliary A/C-Heater ......................................................................................................... ......................................................................................... Fuse A Blower Motor Relay ....................... .............................................................................................................................................................. ............... Fuse F Class I Trailer Running Lamps ................................................................................ .................................................................................................... Fuse P Class II Trailer Running Lamps Relay ........................................................................................................................................ ................................ Fuse P Daytime Running Lamps Module ........................................................... .................................................................................................................... Fuse R Electronic Brake . .............................................................................................................................................................. .......................................... Fuse D Fuse 1 .......................................................................................... ................................................................................................................................ Fuse S Fuse 10 .. .............................................................................................................................................................. ........................................................ Fuse F Fuse 12 .......................................................................... .............................................................................................................................................. Fuse S Fuse 15 ................................................................................................................................................ ........................................................................ Fuse G Fuse 16 .......................................................... .............................................................................................................................................................. Fuse S Fuse 4 ..................................................................................................................................... ..................................................................................... Fuse S Fuse 8 ............................................... .............................................................................................................................................................. ............. Fuse S Fuse R ....................................................................................................................... ................................................................................................... Fuse S Heated Oxygen Sensor ....... .............................................................................................................................................................. ........................... Fuse G Hood Lamp ................................................................................................. ................................................................................................................ Fuse R Horn Relay ............. .............................................................................................................................................................. ....................................... Fuse R Ignition Switch ................................................................................. ........................................................................................................................... Fuse G Ignition System ................................................................................................................................................. .......................................................... Fuse U Instrument Cluster ........................................................ ............................................................................................................................................... Fuse U Main Light Switch ................................................................................................................................ ....................................................................... Fuse S Modified Vehicle Power ................................... .................................................................................................................................................... Fuse B & J PCM Power Relay ...................................................................................................................... ................................................................................ Fuse U Plug-in Diode ......................................... .............................................................................................................................................................. ....... Fuse L Power Lumbar Seats ....................................................................................................... ............................................................................................. Fuse E Power Seats .............................. .............................................................................................................................................................. ..................... Fuse E Remote Keyless Entry Module .......................................................................... ......................................................................................................... Fuse A Trailer Adapter Battery Feed .................................................................................................................................................... ................................... Fuse J Trailer Backup Lamp Relay ................................................................. ....................................................................................................................... Fuse K Trailer Battery Charge Relay ....................................................................................................................................... ................................................ Fuse J Trailer LH Turn/Stop Lamp ..................................................... ................................................................................................................................... Fuse N Trailer RH Turn/Stop Lamp ............................................................................................................................. .......................................................... Fuse M Trailer Running Lamp Relay ........................................ .............................................................................................................................................. Fuse K Fuse A Fuse A - protects the following circuits: ^ Auxiliary A/C-Heater ^ Remote Keyless Entry Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5866 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 Power Distribution Fuse B Fuse B - protects the following circuits: ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 Power Distribution Fuse D Fuse D - protects the following circuits: ^ Electronic Brake Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5875 Power Distribution Fuse E Fuse E - protects the following circuits: ^ Power Seats ^ Power Lumbar Seats Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5876 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5877 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5878 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5879 Power Distribution Fuse F Fuse F - protects the following circuits: ^ Blower Motor Relay ^ Fuse 10 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5880 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5881 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5882 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 Power Distribution Fuse G Fuse G - protects the following circuits: ^ Ignition Switch ^ Fuse 15 ^ Heated Oxygen Sensor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 Power Distribution Fuse J Fuse J - protects the following circuits: ^ Trailer Battery Charge Relay ^ Trailer Adapter Battery Feed ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5889 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 Power Distribution Fuse K Fuse K - protects the following circuits: ^ Trailer Backup Lamp Relay ^ Trailer Running Lamp Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 Power Distribution Fuse M Fuse M - protects the following circuits: ^ Trailer RH Turn/Stop Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5898 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5899 Power Distribution Fuse N Fuse N - protects the following circuits: ^ Trailer LH Turn/Stop Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5900 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5901 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5902 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5903 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5904 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5905 Power Distribution Fuse P Fuse P - protects the following circuits: ^ Class I Trailer Running Lamps ^ Class II Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5906 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5907 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5908 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5909 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5910 Power Distribution Fuse S Fuse S - protects the following circuits: ^ Fuse 1 ^ Fuse 4 ^ Fuse 8 ^ Fuse 12 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5911 ^ Fuse 16 ^ Fuse R ^ Main Light Switch Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5912 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5913 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5914 Power Distribution Fuse U Fuse U - protects the following circuits: ^ Ignition System ^ Instrument Cluster ^ Part In Assembly Engine ^ PCM Power Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5915 ^ 4 Wheel Anti-Lock Brakes System Relay Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5916 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5917 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5918 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5919 Power Distribution Fuse V Fuse V - protects the following circuits: ^ 4 Wheel Anti-Lock Brakes System Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5920 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5921 Power Distribution Circuit-to-Fuse Cross Reference Accessory Tap ..................................................................................................................................... ........................................................................ Fuse 6 Air Bag Module ............................................... ................................................................................................................................................... Fuse 5 & 15 Anti-Theft Indicator ................................................................................................................... .................................................................................. Fuse 8 Anti-Theft Module ................................. .............................................................................................................................................................. . Fuse 6 & 7 Auxiliary Battery Relay .................................................................................................... ........................................................................................... Fuse 5 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5922 Backup Lamps ..................................................................................................................................... ........................................................................ Fuse 5 Blend Door Actuator ....................................... ............................................................................................................................................................ Fuse 9 Brake Pressure Switch ............................................................................................................ ..................................................................................... Fuse 1 Cigar Lighter ...................................... .............................................................................................................................................................. .......... Fuse 10 Courtesy Lamp Switch ................................................................................................ ................................................................................................. Fuse 8 Data Link Connector .............. .............................................................................................................................................................. ........................ Fuse 1 Daytime Running Lamps Module ................................................................... ............................................................................................................. Fuse 5 Dome/Map Lamp ....... .............................................................................................................................................................. .................................... Fuse 8 Flash to Pass ...................................................................................... .......................................................................................................................... Fuse 4 Function Selector Switch .................................................................................................................................... ......................................................... Fuse 9 Hazard Lamps ............................................................... ............................................................................................................................................... Fuse 5 Head and Park Lamp ........................................................................................................................... ........................................................................ Fuse 4 Illuminated Entry ............................................. ..................................................................................................................................................... Fuse 6 & 8 Instrument Illumination ............................................................................................................... ................................................................................. Fuse 4 Instrument Panel Illumination Lamps .... .............................................................................................................................................................. ...... Fuse 13 License Lamps ............................................................................................................... .............................................................................................. Fuse 4 Main Light Switch ..................... .............................................................................................................................................................. .................. Fuse 11 Modified Vehicle Power ...................................................................................... ...................................................................................................... Fuse 16 Park/Neutral Position Switch .................................................................................................................................................. ..................................... Fuse 7 Power Amplifier ................................................................................. ....................................................................................................................... Fuse 10 Power Lumbar Seats ................................................................................................................................................... ............................................... Fuse 16 Power Mirrors ........................................................................ ...................................................................................................................................... Fuse 8 Powertrain Control Module .................................................................................................................. ....................................................................... Fuse 7 Programmable Speedometer/Odometer Module ................................................................................................................................................. Fuse 1 & 17 Radio ............................................................................................................................... .......................................................................................... Fuse 11 Radio Memory ............................ .............................................................................................................................................................. ................... Fuse 8 Rear Anti-Lock Brakes System ............................................................................ ...................................................................................................... Fuse 17 Rear Power Outlet .......... .............................................................................................................................................................. .............................. Fuse 10 Remote Keyless Entry Module ............................................................... .............................................................................................................. Fuse 6 & 8 Shift Lock Actuator ............................................................................................................................................... ...................................................... Fuse 5 Speed Control ................................................................... .................................................................................................................................... Fuse 1 & 6 Trailer Battery Charge Relay ............................................................................................................... ........................................................................ Fuse 6 Transmission Control Switch .......................... ............................................................................................................................................................. Fuse 5 Transmission Range Sensor ................................................................................................... ...................................................................................... Fuse 7 Turn Lamps ...................................... .............................................................................................................................................................. .............. Fuse 5 Turn/Stop/Hazard Lamp ........................................................................................... ................................................................................................... Fuse 1 Visor Lamps ......................... .............................................................................................................................................................. ......................... Fuse 8 Warning Chime .............................................................................................. ............................................................................................................ Fuse 18 Warning Indicators .... .............................................................................................................................................................. .................................. Fuse 18 Windshield Wiper Motor ..................................................................... ........................................................................................................................ Fuse 2 Wiper Control Module ................................................................................................................................................. ................................................ Fuse 2 Fuse 1 Fuse 1 - protects the following circuits: ^ Turn/Stop/Hazard Lamp ^ Speed Control ^ Data Link Connector ^ Brake Pressure Switch ^ Programmable Speedometer/Odometer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5923 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5924 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5925 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5926 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5927 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Windshield Wiper Motor ^ Wiper Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5928 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5929 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5930 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5931 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ License Lamps ^ Flash to Pass ^ Instrument Illumination ^ Head and Park Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5932 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5933 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5934 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5935 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5936 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Air Bag Module ^ Daytime Running Lamps Module ^ Auxiliary Battery Relay ^ Shift Lock Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5937 ^ Transmission Control Switch ^ Backup Lamps ^ Turn Lamps ^ Hazard Lamps Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5938 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5939 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5942 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5943 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Speed Control ^ Remote Keyless Entry Module ^ Illuminated Entry ^ Accessory Tap Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5944 ^ Anti-Theft Module ^ Trailer Battery Charge Relay Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5945 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5946 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5947 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5948 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: ^ Anti-Theft Module ^ Transmission Range Sensor ^ Park/Neutral Position Switch ^ Powertrain Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5949 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5950 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5951 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5952 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5953 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Courtesy Lamp Switch ^ Illuminated Entry ^ Power Mirrors ^ Visor Lamps Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5954 ^ Anti-Theft Indicator ^ Radio Memory ^ Dome/Map Lamp ^ Remote Keyless Entry Module Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5955 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5956 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5957 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5958 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5959 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5960 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: ^ Function Selector Switch ^ Blend Door Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5961 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5962 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5963 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5964 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: ^ Cigar Lighter ^ Rear Power Outlet ^ Power Amplifier Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5965 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5966 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5967 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5968 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Radio ^ Main Light Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5969 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5970 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5971 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5972 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5973 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Instrument Panel Illumination Lamps Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5974 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5975 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5976 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5977 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5978 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Air Bag Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5979 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5980 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5981 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5982 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Power Lumbar Seats ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5983 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5984 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5985 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Rear Anti-Lock Brakes System ^ Programmable Speedometer/Odometer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5986 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5987 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5988 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5989 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5990 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Warning Indicators ^ Warning Chime Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5991 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5992 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5993 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5994 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5995 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations The interior fuse panel is located on a mounting bracket under the instrument panel, left of the steering column. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6001 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6002 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6003 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6004 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6005 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6006 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6007 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6008 Fuse Block: Electrical Diagrams Interior Fuse Panel Circuit-to-Fuse Cross Reference 4 Wheel Anti-Lock Brakes System Relay ........................................................................................................................................................... Fuse U & V Auxiliary A/C-Heater ......................................................................................................... ......................................................................................... Fuse A Blower Motor Relay ....................... .............................................................................................................................................................. ............... Fuse F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6009 Class I Trailer Running Lamps ............................................................................................................ ........................................................................ Fuse P Class II Trailer Running Lamps Relay ............ ............................................................................................................................................................ Fuse P Daytime Running Lamps Module ............................................................................................ ................................................................................... Fuse R Electronic Brake .................................. .............................................................................................................................................................. ......... Fuse D Fuse 1 ........................................................................................................................... ............................................................................................... Fuse S Fuse 10 ................................... .............................................................................................................................................................. ....................... Fuse F Fuse 12 ........................................................................................................... ............................................................................................................. Fuse S Fuse 15 ..................... .............................................................................................................................................................. ..................................... Fuse G Fuse 16 ............................................................................................. ........................................................................................................................... Fuse S Fuse 4 ......... .............................................................................................................................................................. ................................................... Fuse S Fuse 8 ................................................................................. ......................................................................................................................................... Fuse S Fuse R ................................................................................................................................................. ......................................................................... Fuse S Heated Oxygen Sensor ................................. .............................................................................................................................................................. . Fuse G Hood Lamp ........................................................................................................................... ...................................................................................... Fuse R Horn Relay ....................................... .............................................................................................................................................................. ............. Fuse R Ignition Switch ........................................................................................................... ................................................................................................. Fuse G Ignition System ..................... .............................................................................................................................................................. ........................ Fuse U Instrument Cluster .......................................................................................... ............................................................................................................. Fuse U Main Light Switch ...... .............................................................................................................................................................. ................................... Fuse S Modified Vehicle Power ....................................................................... ................................................................................................................ Fuse B & J PCM Power Relay ................................................................................................................................................... ................................................... Fuse U Plug-in Diode ...................................................................... ........................................................................................................................................ Fuse L Power Lumbar Seats ........................................................................................................................... ......................................................................... Fuse E Power Seats .................................................. .............................................................................................................................................................. . Fuse E Remote Keyless Entry Module .............................................................................................. ..................................................................................... Fuse A Trailer Adapter Battery Feed ............. .............................................................................................................................................................. ............ Fuse J Trailer Backup Lamp Relay ........................................................................................ ................................................................................................ Fuse K Trailer Battery Charge Relay .. .............................................................................................................................................................. ....................... Fuse J Trailer LH Turn/Stop Lamp .............................................................................. .......................................................................................................... Fuse N Trailer RH Turn/Stop Lamp .................................................................................................................................................... ................................... Fuse M Trailer Running Lamp Relay ............................................................... ....................................................................................................................... Fuse K Fuse A Fuse A - protects the following circuits: ^ Auxiliary A/C-Heater ^ Remote Keyless Entry Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6010 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6011 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6012 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6013 Power Distribution Fuse B Fuse B - protects the following circuits: ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6014 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6015 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6016 Power Distribution Fuse D Fuse D - protects the following circuits: ^ Electronic Brake Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6017 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6018 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6019 Power Distribution Fuse E Fuse E - protects the following circuits: ^ Power Seats ^ Power Lumbar Seats Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6020 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6021 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6022 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6023 Power Distribution Fuse F Fuse F - protects the following circuits: ^ Blower Motor Relay ^ Fuse 10 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6024 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6025 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6026 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6027 Power Distribution Fuse G Fuse G - protects the following circuits: ^ Ignition Switch ^ Fuse 15 ^ Heated Oxygen Sensor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 Power Distribution Fuse J Fuse J - protects the following circuits: ^ Trailer Battery Charge Relay ^ Trailer Adapter Battery Feed ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 Power Distribution Fuse K Fuse K - protects the following circuits: ^ Trailer Backup Lamp Relay ^ Trailer Running Lamp Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6037 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6038 Power Distribution Fuse M Fuse M - protects the following circuits: ^ Trailer RH Turn/Stop Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6039 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6040 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6041 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6042 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6043 Power Distribution Fuse N Fuse N - protects the following circuits: ^ Trailer LH Turn/Stop Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6044 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6046 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 Power Distribution Fuse P Fuse P - protects the following circuits: ^ Class I Trailer Running Lamps ^ Class II Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6054 Power Distribution Fuse S Fuse S - protects the following circuits: ^ Fuse 1 ^ Fuse 4 ^ Fuse 8 ^ Fuse 12 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6055 ^ Fuse 16 ^ Fuse R ^ Main Light Switch Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6056 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6057 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6058 Power Distribution Fuse U Fuse U - protects the following circuits: ^ Ignition System ^ Instrument Cluster ^ Part In Assembly Engine ^ PCM Power Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6059 ^ 4 Wheel Anti-Lock Brakes System Relay Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6060 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6061 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6062 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6063 Power Distribution Fuse V Fuse V - protects the following circuits: ^ 4 Wheel Anti-Lock Brakes System Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6064 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6065 Power Distribution Circuit-to-Circuit Breaker Cross Reference Anti-Theft Module ................................................................................................................................ .................................................... Circuit Breaker 12 Memory Lock Module ....................................... ....................................................................................................................................... Circuit Breaker 12 Power Door Locks ............................................................................................................. ....................................................................... Circuit Breaker 12 Power Windows ............................. ........................................................................................................................................................... Circuit Breaker 14 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6066 Circuit Breaker 12 Circuit Breaker 12 - protects the following circuits: ^ Anti-Theft Module ^ Power Door Locks ^ Memory Lock Module Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6067 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6068 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6069 Power Distribution Circuit Breaker 14 Circuit Breaker 14 - protects the following circuits: ^ Power Windows Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6074 Power Distribution Circuit-to-Fuse Cross Reference Accessory Tap ..................................................................................................................................... ........................................................................ Fuse 6 Air Bag Module ............................................... ................................................................................................................................................... Fuse 5 & 15 Anti-Theft Indicator ................................................................................................................... .................................................................................. Fuse 8 Anti-Theft Module ................................. .............................................................................................................................................................. . Fuse 6 & 7 Auxiliary Battery Relay .................................................................................................... ........................................................................................... Fuse 5 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 Backup Lamps ..................................................................................................................................... ........................................................................ Fuse 5 Blend Door Actuator ....................................... ............................................................................................................................................................ Fuse 9 Brake Pressure Switch ............................................................................................................ ..................................................................................... Fuse 1 Cigar Lighter ...................................... .............................................................................................................................................................. .......... Fuse 10 Courtesy Lamp Switch ................................................................................................ ................................................................................................. Fuse 8 Data Link Connector .............. .............................................................................................................................................................. ........................ Fuse 1 Daytime Running Lamps Module ................................................................... ............................................................................................................. Fuse 5 Dome/Map Lamp ....... .............................................................................................................................................................. .................................... Fuse 8 Flash to Pass ...................................................................................... .......................................................................................................................... Fuse 4 Function Selector Switch .................................................................................................................................... ......................................................... Fuse 9 Hazard Lamps ............................................................... ............................................................................................................................................... Fuse 5 Head and Park Lamp ........................................................................................................................... ........................................................................ Fuse 4 Illuminated Entry ............................................. ..................................................................................................................................................... Fuse 6 & 8 Instrument Illumination ............................................................................................................... ................................................................................. Fuse 4 Instrument Panel Illumination Lamps .... .............................................................................................................................................................. ...... Fuse 13 License Lamps ............................................................................................................... .............................................................................................. Fuse 4 Main Light Switch ..................... .............................................................................................................................................................. .................. Fuse 11 Modified Vehicle Power ...................................................................................... ...................................................................................................... Fuse 16 Park/Neutral Position Switch .................................................................................................................................................. ..................................... Fuse 7 Power Amplifier ................................................................................. ....................................................................................................................... Fuse 10 Power Lumbar Seats ................................................................................................................................................... ............................................... Fuse 16 Power Mirrors ........................................................................ ...................................................................................................................................... Fuse 8 Powertrain Control Module .................................................................................................................. ....................................................................... Fuse 7 Programmable Speedometer/Odometer Module ................................................................................................................................................. Fuse 1 & 17 Radio ............................................................................................................................... .......................................................................................... Fuse 11 Radio Memory ............................ .............................................................................................................................................................. ................... Fuse 8 Rear Anti-Lock Brakes System ............................................................................ ...................................................................................................... Fuse 17 Rear Power Outlet .......... .............................................................................................................................................................. .............................. Fuse 10 Remote Keyless Entry Module ............................................................... .............................................................................................................. Fuse 6 & 8 Shift Lock Actuator ............................................................................................................................................... ...................................................... Fuse 5 Speed Control ................................................................... .................................................................................................................................... Fuse 1 & 6 Trailer Battery Charge Relay ............................................................................................................... ........................................................................ Fuse 6 Transmission Control Switch .......................... ............................................................................................................................................................. Fuse 5 Transmission Range Sensor ................................................................................................... ...................................................................................... Fuse 7 Turn Lamps ...................................... .............................................................................................................................................................. .............. Fuse 5 Turn/Stop/Hazard Lamp ........................................................................................... ................................................................................................... Fuse 1 Visor Lamps ......................... .............................................................................................................................................................. ......................... Fuse 8 Warning Chime .............................................................................................. ............................................................................................................ Fuse 18 Warning Indicators .... .............................................................................................................................................................. .................................. Fuse 18 Windshield Wiper Motor ..................................................................... ........................................................................................................................ Fuse 2 Wiper Control Module ................................................................................................................................................. ................................................ Fuse 2 Fuse 1 Fuse 1 - protects the following circuits: ^ Turn/Stop/Hazard Lamp ^ Speed Control ^ Data Link Connector ^ Brake Pressure Switch ^ Programmable Speedometer/Odometer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Windshield Wiper Motor ^ Wiper Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ License Lamps ^ Flash to Pass ^ Instrument Illumination ^ Head and Park Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6088 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6089 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Air Bag Module ^ Daytime Running Lamps Module ^ Auxiliary Battery Relay ^ Shift Lock Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6090 ^ Transmission Control Switch ^ Backup Lamps ^ Turn Lamps ^ Hazard Lamps Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6091 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6092 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6093 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6094 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6095 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Speed Control ^ Remote Keyless Entry Module ^ Illuminated Entry ^ Accessory Tap Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 ^ Anti-Theft Module ^ Trailer Battery Charge Relay Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6099 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: ^ Anti-Theft Module ^ Transmission Range Sensor ^ Park/Neutral Position Switch ^ Powertrain Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Courtesy Lamp Switch ^ Illuminated Entry ^ Power Mirrors ^ Visor Lamps Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 ^ Anti-Theft Indicator ^ Radio Memory ^ Dome/Map Lamp ^ Remote Keyless Entry Module Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6108 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6109 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6110 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6111 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: ^ Function Selector Switch ^ Blend Door Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: ^ Cigar Lighter ^ Rear Power Outlet ^ Power Amplifier Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Radio ^ Main Light Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Instrument Panel Illumination Lamps Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Air Bag Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Power Lumbar Seats ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Rear Anti-Lock Brakes System ^ Programmable Speedometer/Odometer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Warning Indicators ^ Warning Chime Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 6149 Fuse Block: Application and ID Fuses and Circuit Breakers Location and Values The following circuit protection charts give the location and values of all the circuits containing fuses or circuit breakers. Conventional Chassis Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 6150 Fuse Panel, E-250 Commercial Chassis and E-350 RV Chassis Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations Fusible Link: Locations The fuseable links are located in the Power distribution box, on the lefthand fender apron. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions Fusible Link: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6159 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6160 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6161 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6162 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 Fusible Link: Electrical Diagrams Fuse Link A Fuse Link A - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 Fuse Link B Fuse Link B - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Power Distribution Fuse Link C Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 Fuse Link C - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Power Distribution Fuse Link D Fuse Link D - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6166 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 Power Distribution Fuse Link E Fuse Link E - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 Power Distribution Fuse Link F Fuse Link F - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 Power Distribution Fuse Link G Fuse Link G - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6173 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Weather Pack Connector Seals Multiple Junction Connector: Technical Service Bulletins Electrical - Weather Pack Connector Seals Article No. 96-6-10 3-11-96 ^ ELECTRICAL PARTS-WEATHER PACK CONNECTOR SEALS-VEHICLES WITH 7.3L DI TURBO-SERVICE TIP ^ WIRING-ELECTRICAL PARTS-WEATHER PACK CONNECTOR SEALS-VEHICLES WITH 7.3L DI TURBO-SERVICE TIP ^ ELECTRICAL PARTS-WEATHER PACK CONNECTOR SEALS-VEHICLES WITH 7.3L DI TURBO-SERVICE TIP LIGHT TRUCK: 1994-96 F SUPER DUTY, F-250, F-35O 1995-96 ECONOLINE ISSUE: Some warranty-replaced electrical parts are being returned to Ford Motor Company with weather pack connector seals. The seals are needed to keep contaminants out of the connector and maintain good electrical performance. ACTION: When replacing electrical parts such as injectors, ICP sensors, glow plug relays, EOT sensors, etc., make sure the weather pack connector seals (blue, green or gray) are left on the wiring harness and not returned with the parts. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 Multiple Junction Connector: Diagrams C100 In Line Connector Faces - C100M Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6180 In Line Connector Faces - C100F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6181 In Line Connector Faces - C119 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6182 Multiple Junction Connector: Diagrams C121 In Line Connector Faces - C121M Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6183 In Line Connector Faces - C121F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6184 In Line Connector Faces - C133 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6185 Multiple Junction Connector: Diagrams In Line Connector Faces - C100M Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6186 In Line Connector Faces - C100F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6187 In Line Connector Faces - C119 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6188 In Line Connector Faces - C121M Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6189 In Line Connector Faces - C121F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6190 In Line Connector Faces - C133 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6191 In Line Connector Faces - C134 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6192 In Line Connector Faces - C150 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6193 In Line Connector Faces - C173 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6194 In Line Connector Faces - C192 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6195 In Line Connector Faces - C202M (With Premium Sound) In Line Connector Faces - C202F (With Premium Sound) In Line Connector Faces - C202M (Without Premium Sound) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6196 In Line Connector Faces - C202F (Without Premium Sound) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6197 In Line Connector Faces - C206 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6198 In Line Connector Faces - C212M Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6199 In Line Connector Faces - C212F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6200 In Line Connector Faces - C234M Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6201 In Line Connector Faces - C234F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6202 In Line Connector Faces - C305 In Line Connector Faces - C306M (With Premium Sound) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6203 In Line Connector Faces - C306F In Line Connector Faces - C306F In Line Connector Faces - C306M (Without Premium Sound) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6204 In Line Connector Faces - C307 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6205 In Line Connector Faces - C322 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6206 In Line Connector Faces - C323/C324 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6207 In Line Connector Faces - C325 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6208 In Line Connector Faces - C339 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6209 In Line Connector Faces - C353 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6210 In Line Connector Faces - C404 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6211 In Line Connector Faces - C413 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6212 In Line Connector Faces - C1014 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6217 Power Distribution Relay: Locations Auxiliary Battery Relay The Auxiliary Battery Relay is located at the LH side of the engine compartment, below headlamp. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6218 Power Distribution Relay: Locations Trailer Backup Lamp Relay Engine Compartment View The Trailer Backup Lamp Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6219 Power Distribution Relay: Locations Trailer Battery Charge Relay Engine Compartment View The Trailer Battery Charge Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6220 Power Distribution Relay: Locations Trailer Running Lamp Relay Engine Compartment View The Trailer Running Lamp Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay Trailer Battery Charge Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay > Page 6223 Trailer Backup Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay > Page 6224 Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6230 Power Distribution Relay: Locations Auxiliary Battery Relay The Auxiliary Battery Relay is located at the LH side of the engine compartment, below headlamp. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6231 Power Distribution Relay: Locations Trailer Backup Lamp Relay Engine Compartment View The Trailer Backup Lamp Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6232 Power Distribution Relay: Locations Trailer Battery Charge Relay Engine Compartment View The Trailer Battery Charge Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6233 Power Distribution Relay: Locations Trailer Running Lamp Relay Engine Compartment View The Trailer Running Lamp Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay Trailer Battery Charge Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay > Page 6236 Trailer Backup Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay > Page 6237 Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Location An engine compartment power distribution box is located near the lower left-hand fender apron. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Location An engine compartment power distribution box is located near the lower left-hand fender apron. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6249 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6250 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6251 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6252 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6253 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6254 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6255 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 6256 Circuit Breaker: Electrical Diagrams Circuit Breaker 12 For wiring diagrams, please refer to Starting and Charging/Power and Ground Distribution/Diagrams/Electrical/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit Breaker 12. See: Diagrams/Electrical Diagrams/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit Breaker 12 Circuit Breaker 14 For wiring diagrams, please refer to Starting and Charging/Power and Ground Distribution/Diagrams/Electrical/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit Breaker 14. See: Diagrams/Electrical Diagrams/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit Breaker 14 Circuit-To-Circuit Breaker Cross Reference For wiring diagrams, please refer to Starting and Charging/Power and Ground Distribution/Diagrams/Electrical/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit-to-Circuit Breaker Cross Reference. See: Diagrams/Electrical Diagrams/Power Distribution/Interior Fuse Panel/Circuit Breaker Circuits/Circuit-to-Circuit Breaker Cross Reference Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement Article No. 96-24-6 11/18/96 WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350 SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE This TSB article is being republished in its entirety to update the applicable model years. ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved Ford service diode. Some electrical diodes used in early production vehicles are color coded for the purpose of size identification while others are stamped with a manufacture number. All Ford service diodes and current production diodes are identified by manufacture number. ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the following Electrical Diode Application Chart for the correct service part number. NOTE: IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 6261 ELECTRICAL DIODE APPLICATION CHART PART NUMBER PART NAME E8DZ-10C912-A Diode - 1.0 Amp - 400V E8DZ-10C912-B Diode - 6.0 Amp - 400V OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-2-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 2770 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6270 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6271 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6272 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6273 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6274 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6275 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6276 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Customer Interest: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6277 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > Component Information > Description and Operation Control Module: Description and Operation Power Control Module (PCM). Description The operation of the E4OD automatic transmission is controlled by the PCM. Many input sensors provide information to the PCM, which then controls the actuators which affect transmission operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 95234 > Nov > 95 > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 95234 > Nov > 95 > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6289 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 95234 > Nov > 95 > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6290 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 95234 > Nov > 95 > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6291 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 95234 > Nov > 95 > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6292 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 95234 > Nov > 95 > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6293 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 95234 > Nov > 95 > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6294 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 95234 > Nov > 95 > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6295 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 95234 > Nov > 95 > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6296 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6307 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6308 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6309 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6310 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6311 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6312 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6313 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > Customer Interest for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6314 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6320 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6321 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6322 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6323 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6324 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6325 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6326 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Radio Capacitor <--> [Electronic Noise Suppressor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio Capacitor: > 9584 > Apr > 95 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Capacitor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6327 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 961418 > Jul > 96 > Mega Fuse - Vibration Breakage Fuse: Customer Interest Mega Fuse - Vibration Breakage Article No. 96-14-18 07/01/96 MEGA FUSE - VIBRATION CAUSES MEGA FUSE TO OPEN - AMBULANCE CONVERSIONS WITH 7.3L DIT ONLY LIGHT TRUCK: 1995-96 E-350 ISSUE: Ambulance conversion companies modify the electrical distribution system in E-350 vehicles with 7.3L DIT engines. These modifications to the original equipment wiring in the area of the Mega Fuse may decrease the strain relief which results in vibration of the Mega Fuse. This vibration may lead to breakage of the fuse at the point of highest stress. ACTION: Replace the Mega Fuse (Figure 1) with a shunt. The shunt should reduce the possibility of fuse breakage caused by vibration. Refer to the following text for details. Contact the original conversion company to discuss the replacement of the Mega Fuse. If the original conversion company approves of the replacement, remove the Mega Fuse and replace it with a shunt. Torque the Mega Fuse holder to 12-18 N-m (9-13 lb-ft). PART NUMBER PART NAME F6UZ-11A086-AA Shunt OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961418A Install Shunt 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 11A086 X6 OASIS CODES: 203000, 203200, 603300, 607000, 614000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 961418 > Jul > 96 > Mega Fuse - Vibration Breakage Fuse: All Technical Service Bulletins Mega Fuse - Vibration Breakage Article No. 96-14-18 07/01/96 MEGA FUSE - VIBRATION CAUSES MEGA FUSE TO OPEN - AMBULANCE CONVERSIONS WITH 7.3L DIT ONLY LIGHT TRUCK: 1995-96 E-350 ISSUE: Ambulance conversion companies modify the electrical distribution system in E-350 vehicles with 7.3L DIT engines. These modifications to the original equipment wiring in the area of the Mega Fuse may decrease the strain relief which results in vibration of the Mega Fuse. This vibration may lead to breakage of the fuse at the point of highest stress. ACTION: Replace the Mega Fuse (Figure 1) with a shunt. The shunt should reduce the possibility of fuse breakage caused by vibration. Refer to the following text for details. Contact the original conversion company to discuss the replacement of the Mega Fuse. If the original conversion company approves of the replacement, remove the Mega Fuse and replace it with a shunt. Torque the Mega Fuse holder to 12-18 N-m (9-13 lb-ft). PART NUMBER PART NAME F6UZ-11A086-AA Shunt OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961418A Install Shunt 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 11A086 X6 OASIS CODES: 203000, 203200, 603300, 607000, 614000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6350 Fuse: Electrical Diagrams Circuit-to-Fuse Cross Reference 4 Wheel Anti-Lock Brakes System Relay ........................................................................................................................................................... Fuse U & V Auxiliary A/C-Heater ......................................................................................................... ......................................................................................... Fuse A Blower Motor Relay ....................... .............................................................................................................................................................. ............... Fuse F Class I Trailer Running Lamps ................................................................................ .................................................................................................... Fuse P Class II Trailer Running Lamps Relay ........................................................................................................................................ ................................ Fuse P Daytime Running Lamps Module ........................................................... .................................................................................................................... Fuse R Electronic Brake . .............................................................................................................................................................. .......................................... Fuse D Fuse 1 .......................................................................................... ................................................................................................................................ Fuse S Fuse 10 .. .............................................................................................................................................................. ........................................................ Fuse F Fuse 12 .......................................................................... .............................................................................................................................................. Fuse S Fuse 15 ................................................................................................................................................ ........................................................................ Fuse G Fuse 16 .......................................................... .............................................................................................................................................................. Fuse S Fuse 4 ..................................................................................................................................... ..................................................................................... Fuse S Fuse 8 ............................................... .............................................................................................................................................................. ............. Fuse S Fuse R ....................................................................................................................... ................................................................................................... Fuse S Heated Oxygen Sensor ....... .............................................................................................................................................................. ........................... Fuse G Hood Lamp ................................................................................................. ................................................................................................................ Fuse R Horn Relay ............. .............................................................................................................................................................. ....................................... Fuse R Ignition Switch ................................................................................. ........................................................................................................................... Fuse G Ignition System ................................................................................................................................................. .......................................................... Fuse U Instrument Cluster ........................................................ ............................................................................................................................................... Fuse U Main Light Switch ................................................................................................................................ ....................................................................... Fuse S Modified Vehicle Power ................................... .................................................................................................................................................... Fuse B & J PCM Power Relay ...................................................................................................................... ................................................................................ Fuse U Plug-in Diode ......................................... .............................................................................................................................................................. ....... Fuse L Power Lumbar Seats ....................................................................................................... ............................................................................................. Fuse E Power Seats .............................. .............................................................................................................................................................. ..................... Fuse E Remote Keyless Entry Module .......................................................................... ......................................................................................................... Fuse A Trailer Adapter Battery Feed .................................................................................................................................................... ................................... Fuse J Trailer Backup Lamp Relay ................................................................. ....................................................................................................................... Fuse K Trailer Battery Charge Relay ....................................................................................................................................... ................................................ Fuse J Trailer LH Turn/Stop Lamp ..................................................... ................................................................................................................................... Fuse N Trailer RH Turn/Stop Lamp ............................................................................................................................. .......................................................... Fuse M Trailer Running Lamp Relay ........................................ .............................................................................................................................................. Fuse K Fuse A Fuse A - protects the following circuits: ^ Auxiliary A/C-Heater ^ Remote Keyless Entry Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6351 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6352 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6353 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6354 Power Distribution Fuse B Fuse B - protects the following circuits: ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6355 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 Power Distribution Fuse D Fuse D - protects the following circuits: ^ Electronic Brake Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 Power Distribution Fuse E Fuse E - protects the following circuits: ^ Power Seats ^ Power Lumbar Seats Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 Power Distribution Fuse F Fuse F - protects the following circuits: ^ Blower Motor Relay ^ Fuse 10 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 Power Distribution Fuse G Fuse G - protects the following circuits: ^ Ignition Switch ^ Fuse 15 ^ Heated Oxygen Sensor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6370 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6371 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 Power Distribution Fuse J Fuse J - protects the following circuits: ^ Trailer Battery Charge Relay ^ Trailer Adapter Battery Feed ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6374 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6375 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6376 Power Distribution Fuse K Fuse K - protects the following circuits: ^ Trailer Backup Lamp Relay ^ Trailer Running Lamp Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6377 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6378 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6379 Power Distribution Fuse M Fuse M - protects the following circuits: ^ Trailer RH Turn/Stop Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6380 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6381 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6382 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6383 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6384 Power Distribution Fuse N Fuse N - protects the following circuits: ^ Trailer LH Turn/Stop Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6385 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6386 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6387 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6388 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6389 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6390 Power Distribution Fuse P Fuse P - protects the following circuits: ^ Class I Trailer Running Lamps ^ Class II Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6391 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6392 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6393 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6394 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6395 Power Distribution Fuse S Fuse S - protects the following circuits: ^ Fuse 1 ^ Fuse 4 ^ Fuse 8 ^ Fuse 12 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6396 ^ Fuse 16 ^ Fuse R ^ Main Light Switch Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6397 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 Power Distribution Fuse U Fuse U - protects the following circuits: ^ Ignition System ^ Instrument Cluster ^ Part In Assembly Engine ^ PCM Power Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 ^ 4 Wheel Anti-Lock Brakes System Relay Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 Power Distribution Fuse V Fuse V - protects the following circuits: ^ 4 Wheel Anti-Lock Brakes System Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 Power Distribution Circuit-to-Fuse Cross Reference Accessory Tap ..................................................................................................................................... ........................................................................ Fuse 6 Air Bag Module ............................................... ................................................................................................................................................... Fuse 5 & 15 Anti-Theft Indicator ................................................................................................................... .................................................................................. Fuse 8 Anti-Theft Module ................................. .............................................................................................................................................................. . Fuse 6 & 7 Auxiliary Battery Relay .................................................................................................... ........................................................................................... Fuse 5 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 Backup Lamps ..................................................................................................................................... ........................................................................ Fuse 5 Blend Door Actuator ....................................... ............................................................................................................................................................ Fuse 9 Brake Pressure Switch ............................................................................................................ ..................................................................................... Fuse 1 Cigar Lighter ...................................... .............................................................................................................................................................. .......... Fuse 10 Courtesy Lamp Switch ................................................................................................ ................................................................................................. Fuse 8 Data Link Connector .............. .............................................................................................................................................................. ........................ Fuse 1 Daytime Running Lamps Module ................................................................... ............................................................................................................. Fuse 5 Dome/Map Lamp ....... .............................................................................................................................................................. .................................... Fuse 8 Flash to Pass ...................................................................................... .......................................................................................................................... Fuse 4 Function Selector Switch .................................................................................................................................... ......................................................... Fuse 9 Hazard Lamps ............................................................... ............................................................................................................................................... Fuse 5 Head and Park Lamp ........................................................................................................................... ........................................................................ Fuse 4 Illuminated Entry ............................................. ..................................................................................................................................................... Fuse 6 & 8 Instrument Illumination ............................................................................................................... ................................................................................. Fuse 4 Instrument Panel Illumination Lamps .... .............................................................................................................................................................. ...... Fuse 13 License Lamps ............................................................................................................... .............................................................................................. Fuse 4 Main Light Switch ..................... .............................................................................................................................................................. .................. Fuse 11 Modified Vehicle Power ...................................................................................... ...................................................................................................... Fuse 16 Park/Neutral Position Switch .................................................................................................................................................. ..................................... Fuse 7 Power Amplifier ................................................................................. ....................................................................................................................... Fuse 10 Power Lumbar Seats ................................................................................................................................................... ............................................... Fuse 16 Power Mirrors ........................................................................ ...................................................................................................................................... Fuse 8 Powertrain Control Module .................................................................................................................. ....................................................................... Fuse 7 Programmable Speedometer/Odometer Module ................................................................................................................................................. Fuse 1 & 17 Radio ............................................................................................................................... .......................................................................................... Fuse 11 Radio Memory ............................ .............................................................................................................................................................. ................... Fuse 8 Rear Anti-Lock Brakes System ............................................................................ ...................................................................................................... Fuse 17 Rear Power Outlet .......... .............................................................................................................................................................. .............................. Fuse 10 Remote Keyless Entry Module ............................................................... .............................................................................................................. Fuse 6 & 8 Shift Lock Actuator ............................................................................................................................................... ...................................................... Fuse 5 Speed Control ................................................................... .................................................................................................................................... Fuse 1 & 6 Trailer Battery Charge Relay ............................................................................................................... ........................................................................ Fuse 6 Transmission Control Switch .......................... ............................................................................................................................................................. Fuse 5 Transmission Range Sensor ................................................................................................... ...................................................................................... Fuse 7 Turn Lamps ...................................... .............................................................................................................................................................. .............. Fuse 5 Turn/Stop/Hazard Lamp ........................................................................................... ................................................................................................... Fuse 1 Visor Lamps ......................... .............................................................................................................................................................. ......................... Fuse 8 Warning Chime .............................................................................................. ............................................................................................................ Fuse 18 Warning Indicators .... .............................................................................................................................................................. .................................. Fuse 18 Windshield Wiper Motor ..................................................................... ........................................................................................................................ Fuse 2 Wiper Control Module ................................................................................................................................................. ................................................ Fuse 2 Fuse 1 Fuse 1 - protects the following circuits: ^ Turn/Stop/Hazard Lamp ^ Speed Control ^ Data Link Connector ^ Brake Pressure Switch ^ Programmable Speedometer/Odometer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Windshield Wiper Motor ^ Wiper Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ License Lamps ^ Flash to Pass ^ Instrument Illumination ^ Head and Park Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6420 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Air Bag Module ^ Daytime Running Lamps Module ^ Auxiliary Battery Relay ^ Shift Lock Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6422 ^ Transmission Control Switch ^ Backup Lamps ^ Turn Lamps ^ Hazard Lamps Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6425 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6426 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6427 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6428 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Speed Control ^ Remote Keyless Entry Module ^ Illuminated Entry ^ Accessory Tap Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 ^ Anti-Theft Module ^ Trailer Battery Charge Relay Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: ^ Anti-Theft Module ^ Transmission Range Sensor ^ Park/Neutral Position Switch ^ Powertrain Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6438 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Courtesy Lamp Switch ^ Illuminated Entry ^ Power Mirrors ^ Visor Lamps Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 ^ Anti-Theft Indicator ^ Radio Memory ^ Dome/Map Lamp ^ Remote Keyless Entry Module Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: ^ Function Selector Switch ^ Blend Door Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: ^ Cigar Lighter ^ Rear Power Outlet ^ Power Amplifier Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6450 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6451 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6452 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Radio ^ Main Light Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Instrument Panel Illumination Lamps Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Air Bag Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Power Lumbar Seats ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6468 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6469 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6470 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Rear Anti-Lock Brakes System ^ Programmable Speedometer/Odometer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6471 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6472 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Warning Indicators ^ Warning Chime Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6476 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6477 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6478 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6479 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6480 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations The interior fuse panel is located on a mounting bracket under the instrument panel, left of the steering column. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6486 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 Fuse Block: Electrical Diagrams Interior Fuse Panel Circuit-to-Fuse Cross Reference 4 Wheel Anti-Lock Brakes System Relay ........................................................................................................................................................... Fuse U & V Auxiliary A/C-Heater ......................................................................................................... ......................................................................................... Fuse A Blower Motor Relay ....................... .............................................................................................................................................................. ............... Fuse F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6494 Class I Trailer Running Lamps ............................................................................................................ ........................................................................ Fuse P Class II Trailer Running Lamps Relay ............ ............................................................................................................................................................ Fuse P Daytime Running Lamps Module ............................................................................................ ................................................................................... Fuse R Electronic Brake .................................. .............................................................................................................................................................. ......... Fuse D Fuse 1 ........................................................................................................................... ............................................................................................... Fuse S Fuse 10 ................................... .............................................................................................................................................................. ....................... Fuse F Fuse 12 ........................................................................................................... ............................................................................................................. Fuse S Fuse 15 ..................... .............................................................................................................................................................. ..................................... Fuse G Fuse 16 ............................................................................................. ........................................................................................................................... Fuse S Fuse 4 ......... .............................................................................................................................................................. ................................................... Fuse S Fuse 8 ................................................................................. ......................................................................................................................................... Fuse S Fuse R ................................................................................................................................................. ......................................................................... Fuse S Heated Oxygen Sensor ................................. .............................................................................................................................................................. . Fuse G Hood Lamp ........................................................................................................................... ...................................................................................... Fuse R Horn Relay ....................................... .............................................................................................................................................................. ............. Fuse R Ignition Switch ........................................................................................................... ................................................................................................. Fuse G Ignition System ..................... .............................................................................................................................................................. ........................ Fuse U Instrument Cluster .......................................................................................... ............................................................................................................. Fuse U Main Light Switch ...... .............................................................................................................................................................. ................................... Fuse S Modified Vehicle Power ....................................................................... ................................................................................................................ Fuse B & J PCM Power Relay ................................................................................................................................................... ................................................... Fuse U Plug-in Diode ...................................................................... ........................................................................................................................................ Fuse L Power Lumbar Seats ........................................................................................................................... ......................................................................... Fuse E Power Seats .................................................. .............................................................................................................................................................. . Fuse E Remote Keyless Entry Module .............................................................................................. ..................................................................................... Fuse A Trailer Adapter Battery Feed ............. .............................................................................................................................................................. ............ Fuse J Trailer Backup Lamp Relay ........................................................................................ ................................................................................................ Fuse K Trailer Battery Charge Relay .. .............................................................................................................................................................. ....................... Fuse J Trailer LH Turn/Stop Lamp .............................................................................. .......................................................................................................... Fuse N Trailer RH Turn/Stop Lamp .................................................................................................................................................... ................................... Fuse M Trailer Running Lamp Relay ............................................................... ....................................................................................................................... Fuse K Fuse A Fuse A - protects the following circuits: ^ Auxiliary A/C-Heater ^ Remote Keyless Entry Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6495 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6496 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6497 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6498 Power Distribution Fuse B Fuse B - protects the following circuits: ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6499 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 Power Distribution Fuse D Fuse D - protects the following circuits: ^ Electronic Brake Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 Power Distribution Fuse E Fuse E - protects the following circuits: ^ Power Seats ^ Power Lumbar Seats Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 Power Distribution Fuse F Fuse F - protects the following circuits: ^ Blower Motor Relay ^ Fuse 10 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 Power Distribution Fuse G Fuse G - protects the following circuits: ^ Ignition Switch ^ Fuse 15 ^ Heated Oxygen Sensor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 Power Distribution Fuse J Fuse J - protects the following circuits: ^ Trailer Battery Charge Relay ^ Trailer Adapter Battery Feed ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 Power Distribution Fuse K Fuse K - protects the following circuits: ^ Trailer Backup Lamp Relay ^ Trailer Running Lamp Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 Power Distribution Fuse M Fuse M - protects the following circuits: ^ Trailer RH Turn/Stop Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6524 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6525 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6526 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6527 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6528 Power Distribution Fuse N Fuse N - protects the following circuits: ^ Trailer LH Turn/Stop Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6529 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6530 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6531 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6532 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6533 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 Power Distribution Fuse P Fuse P - protects the following circuits: ^ Class I Trailer Running Lamps ^ Class II Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 Power Distribution Fuse S Fuse S - protects the following circuits: ^ Fuse 1 ^ Fuse 4 ^ Fuse 8 ^ Fuse 12 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 ^ Fuse 16 ^ Fuse R ^ Main Light Switch Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 Power Distribution Fuse U Fuse U - protects the following circuits: ^ Ignition System ^ Instrument Cluster ^ Part In Assembly Engine ^ PCM Power Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 ^ 4 Wheel Anti-Lock Brakes System Relay Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6548 Power Distribution Fuse V Fuse V - protects the following circuits: ^ 4 Wheel Anti-Lock Brakes System Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6549 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6550 Power Distribution Circuit-to-Circuit Breaker Cross Reference Anti-Theft Module ................................................................................................................................ .................................................... Circuit Breaker 12 Memory Lock Module ....................................... ....................................................................................................................................... Circuit Breaker 12 Power Door Locks ............................................................................................................. ....................................................................... Circuit Breaker 12 Power Windows ............................. ........................................................................................................................................................... Circuit Breaker 14 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6551 Circuit Breaker 12 Circuit Breaker 12 - protects the following circuits: ^ Anti-Theft Module ^ Power Door Locks ^ Memory Lock Module Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6552 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6553 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6554 Power Distribution Circuit Breaker 14 Circuit Breaker 14 - protects the following circuits: ^ Power Windows Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6555 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6556 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6557 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6558 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6559 Power Distribution Circuit-to-Fuse Cross Reference Accessory Tap ..................................................................................................................................... ........................................................................ Fuse 6 Air Bag Module ............................................... ................................................................................................................................................... Fuse 5 & 15 Anti-Theft Indicator ................................................................................................................... .................................................................................. Fuse 8 Anti-Theft Module ................................. .............................................................................................................................................................. . Fuse 6 & 7 Auxiliary Battery Relay .................................................................................................... ........................................................................................... Fuse 5 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6560 Backup Lamps ..................................................................................................................................... ........................................................................ Fuse 5 Blend Door Actuator ....................................... ............................................................................................................................................................ Fuse 9 Brake Pressure Switch ............................................................................................................ ..................................................................................... Fuse 1 Cigar Lighter ...................................... .............................................................................................................................................................. .......... Fuse 10 Courtesy Lamp Switch ................................................................................................ ................................................................................................. Fuse 8 Data Link Connector .............. .............................................................................................................................................................. ........................ Fuse 1 Daytime Running Lamps Module ................................................................... ............................................................................................................. Fuse 5 Dome/Map Lamp ....... .............................................................................................................................................................. .................................... Fuse 8 Flash to Pass ...................................................................................... .......................................................................................................................... Fuse 4 Function Selector Switch .................................................................................................................................... ......................................................... Fuse 9 Hazard Lamps ............................................................... ............................................................................................................................................... Fuse 5 Head and Park Lamp ........................................................................................................................... ........................................................................ Fuse 4 Illuminated Entry ............................................. ..................................................................................................................................................... Fuse 6 & 8 Instrument Illumination ............................................................................................................... ................................................................................. Fuse 4 Instrument Panel Illumination Lamps .... .............................................................................................................................................................. ...... Fuse 13 License Lamps ............................................................................................................... .............................................................................................. Fuse 4 Main Light Switch ..................... .............................................................................................................................................................. .................. Fuse 11 Modified Vehicle Power ...................................................................................... ...................................................................................................... Fuse 16 Park/Neutral Position Switch .................................................................................................................................................. ..................................... Fuse 7 Power Amplifier ................................................................................. ....................................................................................................................... Fuse 10 Power Lumbar Seats ................................................................................................................................................... ............................................... Fuse 16 Power Mirrors ........................................................................ ...................................................................................................................................... Fuse 8 Powertrain Control Module .................................................................................................................. ....................................................................... Fuse 7 Programmable Speedometer/Odometer Module ................................................................................................................................................. Fuse 1 & 17 Radio ............................................................................................................................... .......................................................................................... Fuse 11 Radio Memory ............................ .............................................................................................................................................................. ................... Fuse 8 Rear Anti-Lock Brakes System ............................................................................ ...................................................................................................... Fuse 17 Rear Power Outlet .......... .............................................................................................................................................................. .............................. Fuse 10 Remote Keyless Entry Module ............................................................... .............................................................................................................. Fuse 6 & 8 Shift Lock Actuator ............................................................................................................................................... ...................................................... Fuse 5 Speed Control ................................................................... .................................................................................................................................... Fuse 1 & 6 Trailer Battery Charge Relay ............................................................................................................... ........................................................................ Fuse 6 Transmission Control Switch .......................... ............................................................................................................................................................. Fuse 5 Transmission Range Sensor ................................................................................................... ...................................................................................... Fuse 7 Turn Lamps ...................................... .............................................................................................................................................................. .............. Fuse 5 Turn/Stop/Hazard Lamp ........................................................................................... ................................................................................................... Fuse 1 Visor Lamps ......................... .............................................................................................................................................................. ......................... Fuse 8 Warning Chime .............................................................................................. ............................................................................................................ Fuse 18 Warning Indicators .... .............................................................................................................................................................. .................................. Fuse 18 Windshield Wiper Motor ..................................................................... ........................................................................................................................ Fuse 2 Wiper Control Module ................................................................................................................................................. ................................................ Fuse 2 Fuse 1 Fuse 1 - protects the following circuits: ^ Turn/Stop/Hazard Lamp ^ Speed Control ^ Data Link Connector ^ Brake Pressure Switch ^ Programmable Speedometer/Odometer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6561 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6562 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6563 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6564 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6565 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: ^ Windshield Wiper Motor ^ Wiper Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6566 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6567 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6568 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6569 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: ^ License Lamps ^ Flash to Pass ^ Instrument Illumination ^ Head and Park Lamp Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6572 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6573 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6574 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: ^ Air Bag Module ^ Daytime Running Lamps Module ^ Auxiliary Battery Relay ^ Shift Lock Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6575 ^ Transmission Control Switch ^ Backup Lamps ^ Turn Lamps ^ Hazard Lamps Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 Power Distribution Fuse 6 Fuse 6 - protects the following circuits: ^ Speed Control ^ Remote Keyless Entry Module ^ Illuminated Entry ^ Accessory Tap Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6582 ^ Anti-Theft Module ^ Trailer Battery Charge Relay Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6583 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6584 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6585 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6586 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: ^ Anti-Theft Module ^ Transmission Range Sensor ^ Park/Neutral Position Switch ^ Powertrain Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6587 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6588 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6589 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6590 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6591 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: ^ Courtesy Lamp Switch ^ Illuminated Entry ^ Power Mirrors ^ Visor Lamps Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6592 ^ Anti-Theft Indicator ^ Radio Memory ^ Dome/Map Lamp ^ Remote Keyless Entry Module Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6593 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: ^ Function Selector Switch ^ Blend Door Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: ^ Cigar Lighter ^ Rear Power Outlet ^ Power Amplifier Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6604 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6606 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: ^ Radio ^ Main Light Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6607 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6608 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6610 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: ^ Instrument Panel Illumination Lamps Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6614 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6615 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6616 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: ^ Air Bag Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6617 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6618 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6619 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6620 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: ^ Power Lumbar Seats ^ Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6621 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6622 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6623 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: ^ Rear Anti-Lock Brakes System ^ Programmable Speedometer/Odometer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6624 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6625 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6626 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6627 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6628 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: ^ Warning Indicators ^ Warning Chime Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6631 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6632 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6633 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 6634 Fuse Block: Application and ID Fuses and Circuit Breakers Location and Values The following circuit protection charts give the location and values of all the circuits containing fuses or circuit breakers. Conventional Chassis Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 6635 Fuse Panel, E-250 Commercial Chassis and E-350 RV Chassis Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations Fusible Link: Locations The fuseable links are located in the Power distribution box, on the lefthand fender apron. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions Fusible Link: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6641 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6642 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6643 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6647 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6648 Fusible Link: Electrical Diagrams Fuse Link A Fuse Link A - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6649 Fuse Link B Fuse Link B - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Power Distribution Fuse Link C Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6650 Fuse Link C - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Power Distribution Fuse Link D Fuse Link D - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6651 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 Power Distribution Fuse Link E Fuse Link E - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 Power Distribution Fuse Link F Fuse Link F - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6655 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6656 Power Distribution Fuse Link G Fuse Link G - protects the circuits from the generator/voltage regulator to the battery and the engine compartment fuse panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6657 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 6658 Power Distribution Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Electrical - Weather Pack Connector Seals Multiple Junction Connector: Technical Service Bulletins Electrical - Weather Pack Connector Seals Article No. 96-6-10 3-11-96 ^ ELECTRICAL PARTS-WEATHER PACK CONNECTOR SEALS-VEHICLES WITH 7.3L DI TURBO-SERVICE TIP ^ WIRING-ELECTRICAL PARTS-WEATHER PACK CONNECTOR SEALS-VEHICLES WITH 7.3L DI TURBO-SERVICE TIP ^ ELECTRICAL PARTS-WEATHER PACK CONNECTOR SEALS-VEHICLES WITH 7.3L DI TURBO-SERVICE TIP LIGHT TRUCK: 1994-96 F SUPER DUTY, F-250, F-35O 1995-96 ECONOLINE ISSUE: Some warranty-replaced electrical parts are being returned to Ford Motor Company with weather pack connector seals. The seals are needed to keep contaminants out of the connector and maintain good electrical performance. ACTION: When replacing electrical parts such as injectors, ICP sensors, glow plug relays, EOT sensors, etc., make sure the weather pack connector seals (blue, green or gray) are left on the wiring harness and not returned with the parts. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 Multiple Junction Connector: Diagrams C100 In Line Connector Faces - C100M Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6665 In Line Connector Faces - C100F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6666 In Line Connector Faces - C119 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6667 Multiple Junction Connector: Diagrams C121 In Line Connector Faces - C121M Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6668 In Line Connector Faces - C121F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6669 In Line Connector Faces - C133 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6670 Multiple Junction Connector: Diagrams In Line Connector Faces - C100M Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6671 In Line Connector Faces - C100F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6672 In Line Connector Faces - C119 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6673 In Line Connector Faces - C121M Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6674 In Line Connector Faces - C121F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6675 In Line Connector Faces - C133 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6676 In Line Connector Faces - C134 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6677 In Line Connector Faces - C150 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6678 In Line Connector Faces - C173 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6679 In Line Connector Faces - C192 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6680 In Line Connector Faces - C202M (With Premium Sound) In Line Connector Faces - C202F (With Premium Sound) In Line Connector Faces - C202M (Without Premium Sound) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6681 In Line Connector Faces - C202F (Without Premium Sound) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6682 In Line Connector Faces - C206 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6683 In Line Connector Faces - C212M Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6684 In Line Connector Faces - C212F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6685 In Line Connector Faces - C234M Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6686 In Line Connector Faces - C234F Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6687 In Line Connector Faces - C305 In Line Connector Faces - C306M (With Premium Sound) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6688 In Line Connector Faces - C306F In Line Connector Faces - C306F In Line Connector Faces - C306M (Without Premium Sound) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6689 In Line Connector Faces - C307 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6690 In Line Connector Faces - C322 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6691 In Line Connector Faces - C323/C324 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6692 In Line Connector Faces - C325 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6693 In Line Connector Faces - C339 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6694 In Line Connector Faces - C353 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6695 In Line Connector Faces - C404 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6696 In Line Connector Faces - C413 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 > Page 6697 In Line Connector Faces - C1014 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6702 Power Distribution Relay: Locations Auxiliary Battery Relay The Auxiliary Battery Relay is located at the LH side of the engine compartment, below headlamp. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6703 Power Distribution Relay: Locations Trailer Backup Lamp Relay Engine Compartment View The Trailer Backup Lamp Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6704 Power Distribution Relay: Locations Trailer Battery Charge Relay Engine Compartment View The Trailer Battery Charge Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6705 Power Distribution Relay: Locations Trailer Running Lamp Relay Engine Compartment View The Trailer Running Lamp Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay Trailer Battery Charge Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay > Page 6708 Trailer Backup Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay > Page 6709 Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6715 Power Distribution Relay: Locations Auxiliary Battery Relay The Auxiliary Battery Relay is located at the LH side of the engine compartment, below headlamp. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6716 Power Distribution Relay: Locations Trailer Backup Lamp Relay Engine Compartment View The Trailer Backup Lamp Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6717 Power Distribution Relay: Locations Trailer Battery Charge Relay Engine Compartment View The Trailer Battery Charge Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Power Distribution Box > Page 6718 Power Distribution Relay: Locations Trailer Running Lamp Relay Engine Compartment View The Trailer Running Lamp Relay is located at the lower LH side of the engine compartment, near starter motor relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay Trailer Battery Charge Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay > Page 6721 Trailer Backup Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Diagrams > Trailer Battery Charge Relay > Page 6722 Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Location An engine compartment power distribution box is located near the lower left-hand fender apron. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Location An engine compartment power distribution box is located near the lower left-hand fender apron. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' Alignment: Customer Interest Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 6738 Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 6739 (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 6740 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 6741 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' Alignment: All Technical Service Bulletins Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 6747 Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 6748 (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 6749 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-16-8 > Aug > 02 > Steering/Suspension - Apparent 'Dogtracking' > Page 6750 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6755 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6756 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6757 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6758 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6759 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6760 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6761 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6762 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6763 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6764 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6765 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6766 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6767 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6768 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6769 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6770 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6771 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6772 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6773 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6774 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6775 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6776 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6777 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6778 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6779 Ford E 350 Van 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System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6799 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6800 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6801 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6802 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6803 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6804 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6805 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6806 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6807 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6808 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6809 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6810 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6811 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6812 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6813 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6814 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6815 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6816 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6817 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6818 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6819 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6820 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6821 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6822 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6823 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6824 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6825 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6826 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6827 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6828 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6829 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6830 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6831 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6832 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6833 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6834 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6835 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6836 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6837 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6838 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6839 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6840 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6841 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6842 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6843 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6844 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6845 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6846 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6847 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6848 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6849 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6855 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6856 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6857 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6858 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6859 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6860 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6861 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6862 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6863 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6864 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6865 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6866 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6867 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6868 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6869 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6870 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6871 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6872 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6873 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6874 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6875 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6876 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6877 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6878 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6879 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6880 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6881 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6882 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6883 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6884 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6885 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6886 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6887 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6888 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive 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(V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6893 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6894 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6895 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6896 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6897 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6898 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6899 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6900 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6901 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6902 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6903 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6904 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6905 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6906 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6907 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6908 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6909 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6910 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6911 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6912 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6913 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6914 Ford E 350 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Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6918 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6919 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6920 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service 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Comprehensive Noise/Vibration/Harshness Procedure > Page 6924 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6925 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6926 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6927 Ford E 350 Van 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All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6934 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6935 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6936 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6937 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6938 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6939 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6940 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6941 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6942 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6943 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6944 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6945 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6946 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6947 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6948 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 6949 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 6950 Alignment: By Symptom Technical Service Bulletin # 02-16-8 Date: 020819 Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 6951 front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 6952 (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 6953 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 6954 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Technical Service Bulletin # 02-16-8 Date: 020819 Steering/Suspension - Apparent 'Dogtracking' Article No. 02-16-8 08/19/02 SUSPENSION - VEHICLE APPEARS TO DOGTRACK - SERVICE TIP FORD: 1992-2003 E SERIES Article 00-5-10 is being republished in its entirety to update the vehicle model years. ISSUE The customer may report that an E-Series appears to dogtrack. This customer concern is generally due to unique features of an E-Series that combine to create an optical illusion of dogtracking. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can add to the illusion of dogtracking. ACTION Become aware of the unique features that can create the optical illusion of a dogtrack condition. Follow the Service Procedure to determine if a dogtrack condition exists. If a dogtrack condition can be verified, follow the Diagnostic Procedure and Repair Instructions to correct the condition. SERVICE PROCEDURE NOTE DOGTRACK CONDITIONS THAT ARE THE RESULT OF A COLLISION ARE NOT TO BE ADDRESSED USING THIS TSB. DOGTRACKING THAT IS THE RESULT OF A COLLISION MUST BE REPAIRED USING GENERALLY ACCEPTED COLLISION REPAIR TECHNIQUES. NOTE NEARLY ALL CUSTOMER REPORTS OF DOGTRACKING ARE THE RESULT OF THE OPTICAL ILLUSION DOGTRACKING THAT IS COMMON ON THE E-Series. Two unique conditions combine on the E-Series that enhance the optical illusion of dogtracking. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 6955 First: Front wheel track center of tire to center of tire is wider than the rear wheel track. A person traveling behind the vehicle will be able to see both the front wheel and the rear wheel. The rear wheel will appear to be further toward the center of the vehicle (Figure 1). Front wheel track = 1.76m (69.4), rear wheel track = 1.70m (67.0"). Second: The body of the vehicle is widest in the middle and tapers in toward the front and rear of the vehicle. The rear width of the vehicle is nearly 10cm (4 ") narrower than the widest section of the vehicle in the middle. The Supervan (extended length) continues to taper to the rear of the vehicle and magnifies the optical illusion of dogtracking. Because of the taper of the body, a person driving behind the vehicle can see the side of the vehicle. ONLY if a true condition of dogtracking is suspected, follow Service Procedure to verify and repair. NOTE ATTEMPTING TO USE THE FOLLOWING SERVICE PROCEDURE TO REDUCE THE APPEARANCE OF DOGTRACKING ON A VEHICLE THAT IS NOT TRULY DOGTRACKING WILL LEAD TO ALIGNMENT AND TIRE ISSUES. DO NOT USE THIS PROCEDURE UNLESS A TRUE DOGTRACK CONDITION IS VERIFIED! NOTE SOME NON-FORD AFTERMARKET SPRINGS DO NOT HAVE A CENTER BOLT IN THE LEAF SPRING, WHICH CAN CAUSE DOGTRACKING BY NOT CENTERING THE AXLE ON THE LEAF SPRING. UNEVEN LOADING OF THE VEHICLE (LEFT TO RIGHT) CAN ALSO CAUSE DOGTRACKING. DIAGNOSTIC PROCEDURE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 6956 1. Verify the vehicle dogtracks by measuring the rear axle thrust angle (Figure 2) on the vehicle with a calibrated 4-wheel alignment machine. 2. Record reading and follow repair instruction based on reading: a. Thrust angle of 0 to +/- 0.5 degrees (1) Thrust angle less than 0.5 degrees (32 mm/1.25"centerline difference) is in specification b. Thrust angle of +/- 0.51 to 0.8 degrees (1) To modify thrust angle by 0.1 to 0.3 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on the side of the axle which must be moved. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 6957 (b) Adjust the axle by shifting it forward to make contact with the ground pin prior to torque down. c. Thrust angle of +/- 0.81 to 1.0 degrees (1) To modify thrust angle by 0.3 to 0.5 degrees: (a) Modify the spring center bolt head as shown in Figure 3, on both sides of the axle. If the vehicle dogtracks to the right, grind the rear of the right side leaf spring pin and the front of the left side leaf spring pin. Reverse for dogtracking to the left. Follow repair instructions. (b) Adjust the axle so that both ends make contact with the ground pins prior to torque down. d. Thrust angle of +/- 1.01 or greater (1) To modify thrust angle by more than 0.5 degrees: (a) Ensure that 4-wheel alignment is correctly calibrated and re-measure. (b) If reading is the same, have the frame measured and follow generally accepted collision repair procedures to straighten frame. REPAIR INSTRUCTIONS NOTE FOLLOW NORMAL AND CUSTOMARY SAFETY PRECAUTIONS WHEN LIFTING A VEHICLE. TO REVIEW THE SAFETY PRECAUTIONS, REFER TO SECTION 100-02 OF THE E-Series 1998 TO 2003 WORKSHOP MANUAL. 1. Raise the vehicle oft the ground using a frame-mounted hoist or equivalent. Do not hoist the vehicle using the rear axle as a lift point, as you will need the axle to be free for the repair. NOTE PERFORM REPAIR ON ONE SIDE AT A TIME IF ADJUSTMENT TO BOTH SIDES IS NECESSARY. 2. Support the rear axle with jack stands and then remove the U-bolts which attach the rear axle to the rear leaf springs on the side of the axle which will be moved. If the thrust angle is large, both sides of the axle may require adjustment (see diagnostic procedures). Remove the lower shock absorber and bolt from the axle and lower the jack stand on the side of the axle to be adjusted. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 6958 3. Using C-clamps, clamp the leaves of the leaf spring together on both sides of the center bolt and remove the bolt (Figure 4). 4. Reinstall the center bolt and torque the nut to 70 +/- 10 N.m (52 +/- 7 Lb-ft). Push the axle the maximum distance in the direction required to reduce the thrust angle and tighten the U-bolt nuts: 115.5 +/- 17.5 N.m (85 +/- 13 Lb-ft) for 14 mm nuts, 175 +/- 27 N.m (129 +/- 20 Lb-ft) for 16 mm nuts. 5. Reattach the shock absorber and torque to 79 N.m (58 Lb-ft). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 6959 6. Verify the vehicle no longer dogtracks by rerunning the Diagnostic Procedure. SUPERSEDES: 00-5-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021608A Correct Thrust Angle Or 1.6 Hrs. Rear Axle DEALER CODING CONDITION BASIC PART NO. CODE 4210 42 OASIS CODES: 303000 304000, 305000, 390000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 6960 Alignment: Specifications Caster .................................................................................................................................................. ............................................................. +2.0° to +7.5° Camber ................................................................................................................................................ ................................................................. 0° to +1.0° Toe-In, Inch ......................................................................................................................................... ......................................................... -0.19° to +0.31° Ball Joint Wear .................................................................................................................................... ....................................................... 1/32 in to +7.5 in Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber Alignment: Service and Repair Caster and Camber Fig. 4 Removing Caster/Camber Adjustment Sleeve Fig. 5 Caster/Camber Adjustment Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 6963 Fig. 4 Caster/Camber Variation Chart Caster and camber adjustment is possible with adjusters available in 1/2 degree, 1 degree and 1 1/2 degree increments. One adjuster is used to adjust both caster and camber. Refer to Figs. 2 and 3 for adjuster replacement, then to Fig. 4 for adjuster variations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 6964 Alignment: Service and Repair Ride Height 1. Prior to checking caster and camber, ensure vehicle front ride height is within 1/8 inch side to side. Fig. 1 Measuring Ride Height a. If the vehicle ride heights are not within specifications, redistribute load on loaded vehicles or slightly load empty vehicles on one side. b. If the ride heights cannot be brought within specifications, verify correct spring installation. c. The ride height variations stated are for checking purposes only. The vehicle does not have to operate within these specifications. d. 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. 2. If all the above checks have been made, check wheel alignment with suitable alignment equipment. 3. Using the ride heights obtained earlier, compare caster and camber readings to those listed in the Wheel Alignment Specifications. 4. If the caster and camber angles exceed the specifications, inspect front end for damaged suspension components. Replace as necessary. NOTE: Alignment equipment indicates a true reading only when the vehicle's frame is horizontal. Therefore, if the frame is not level (due to tire, spring or load differences), the caster angle reading must be modified to compensate for the frame angles. If the front is higher than the rear, subtract the amount of angle from the reading. If the front is lower than the rear, add the angle. To check frame angle, use a spirit protractor, and take the frame angle measurement on the lower frame flange at the flat area immediately adjacent to the rear spring front hanger. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Removal 1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the disc brake caliper from the rotor and wire it out of the way. 4. Remove the dust cap, cotter pin, nut retainer, nut, washer, and front wheel bearing. 5. Remove the rotor from the front wheel spindle. 6. Remove bearing cone and roller and wheel hub grease seal. Discard the seal. 7. Remove front disc brake rotor shield. 8. Disconnect the steering linkage from the integral front wheel spindle and spindle arm by removing the cotter pin and nut and then removing the front wheel spindle tie rod from the spindle arm with a Tie Rod End Remover or equivalent. 9. Remove the cotter pin and castellated nut from the lower ball joint stud. 10. Remove the nut from the axle clamp bolt and remove the bolt from the axle. 11. Remove the camber adjuster from the upper ball joint stud and axle beam. If required, use Ball Joint Removing Tool or equivalent to remove adjuster. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 6969 CAUTION: Do not use a pickle fork to separate the ball joint from the axle as this will damage the seal and the ball joint socket. 12. Strike the inside area of the axle as shown to pop lower ball joints loose from the axle beam. 13. Remove the front wheel spindle and ball joint from the axle. Installation 1. Place the front wheel spindle and the ball joints into the axle. 2. Install lower ball joint stud nut and tighten to 148-202 N-m (109-149 lb-ft). Continue tightening the castellated nut until it lines up with the hole in the stud. Install the cotter pin. NOTE: If camber adjustment is necessary, special adjusters must be installed. 3. Install the camber adjuster in the upper front wheel spindle over the upper ball joint stud. Align adjuster properly. 4. Install the clamp bolt into the axle boss. Tighten the nut to 87-119 N-m (64-88 lb-ft). 5. Install the front disc brake rotor shield. 6. Pack the bearing cone and roller and front wheel bearing with a lithium-base grease, Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification. 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. 7. Install the bearing cone and roller and wheel hub grease seal. 8. Install the hub and rotor on the front wheel spindle. 9. Install the front wheel bearing, washer and nut. Adjust bearing end play. 10. Install the nut retainer, cotter pin, and dust cap. 11. Install the disc brake caliper. 12. Connect the steering linkage to the front wheel spindle. Tighten the nut to 70-100 N-m (52-74 lb-ft) and advance the nut as required for installation of the cotter pin. 13. Install the wheel and tire assembly. 14. Lower the vehicle. 15. Check and, if necessary, adjust the toe setting. 16. Check the brakes for proper operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Verify power steering pump has been properly filled, then start and run engine until it reaches normal operating temperature. Turn steering wheel to the left and right several times without hitting the stops. Recheck fluid level. If any air bubbles are present, bleed system as follows: 1. Disable ignition by disconnecting coil wire or ICM. 2. Disconnect shutoff solenoid to prevent starting. 3. Crank engine for 30 seconds, check fluid level and add if required. 4. Crank engine for 30 seconds while cycling steering wheel lock to lock. Do not hold steering wheel on its stops. 5. Check fluid level and add fluid if required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications Power Steering Pump: Specifications Model Number ..................................................................................................................................... .................................................. HBC-JX, HBC-KK Minimum Relief Pressure, psi ............................. .......................................................................................................................................................... 1400 Maximum Relief Pressure, psi .................................................................................................... .................................................................................. 1530 Minimum Flow, Gallons/Minute @ 740 psi [01] ............................................................................................................................................................. 1.4 Model Number ..................................................................................................................................... ................................................................... HBC-JY Minimum Relief Pressure, psi ............................ ........................................................................................................................................................... 1450 Maximum Relief Pressure, psi .................................................................................................... .................................................................................. 1530 Minimum Flow, Gallons/Minute @ 740 psi [01] ............................................................................................................................................................. 1.5 Model Number ..................................................................................................................................... .................................................................. HBC-KE Minimum Relief Pressure, psi ............................ ........................................................................................................................................................... 1400 Maximum Relief Pressure, psi .................................................................................................... .................................................................................. 1530 Minimum Flow, Gallons/Minute @ 740 psi [01] ........................................................................................................................................................... 0.95 Maximum Free Flow @ 1500 RPM ............................................................................................. .................................................................................... 2.6 [01] -- Flow depends on pump model, engine RPM & pulley drive ratio. Engine RPM must be set to specification when checking pump minimum flow capacity. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6977 Power Steering Pump: Description and Operation The Ford CII power steering pump is a belt-driven slipper type pump with a fiberglass reinforced nylon power steering oil reservoir. The oil reservoir is attached to the rear side of the pump housing front plate and the power steering pump housing is encased within the housing and reservoir. The power steering pressure hose is attached with a quick connect fitting, located below the filler neck at the outboard side of the power steering oil reservoir. The fitting allows the line to swivel and does not indicate a loose fitting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 1. Place drain pan under power steering pump, then disconnect pressure and return lines from pump. 2. Remove drive belt. 3. On models equipped with A/C, remove pump mounting bracket to A/C compressor mounting bracket attaching bolts. 4. Remove pump and mounting brackets from vehicle. 5. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 6980 Power Steering Pump: Service and Repair Disassembly and Assembly Exploded View Of Power Steering Pump DISASSEMBLE 1. Remove pulley from pump. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 6981 2. Remove outlet fitting, flow control valve and flow control valve spring from pump, then remove reservoir. 3. Place a suitable C-clamp in a vise. 4. Position lower support plate tool No. T78P-3733-A2, or equivalent, over pump rotor shaft. 5. Install upper compressor plate tool No. T78P-3733-A1, or equivalent, into upper portion of C-clamp. Fig. 2 Positioning Pump In C-Clamp 6. While holding compressor tool, place pump assembly into C-clamp with rotor shaft facing downward. 7. Tighten C-clamp until a slight bottoming of valve cover is observed. Fig. 3 Removing Valve Cover Retaining Ring 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. 9. Loosen C-clamp and remove upper compressor plate tool No. T78P-3733-A2, or equivalent, 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. ASSEMBLE 1. Position rotor on rotor shaft splines with triangle detent on rotor counterbore facing upward. 2. Install snap ring into groove on end of rotor shaft. 3. Position insert cam over rotor. Ensure recessed notch on insert cam is facing upward. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 6982 Fig. 4 Installing Slipper Springs 4. With rotor extended upward approximately half out of cam, insert spring into rotor picket. Fig. 5 Installing Slippers 5. Use a slipper to compress spring, then install slipper with groove facing cam. 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(R) Adhesive part No. 242 or 271, or equivalent, to outside diameter of seal and Lockquick(R) NF or T primer, or equivalent, to seal bore in housing. Install rotor shaft seal using seal installer tool No. T78P-3733-A3, or equivalent. 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 6983 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 seal installer tool No. T78P-3733-A3, or equivalent, into rotor shaft hole and press on lower plate lightly until it bottoms in pump housing. This will seat outer O-ring seal. Fig. 6 Assembling Cam, Slippers And Rotor 13. Install cam, 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. Upper Pressure Plate Installation Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 6984 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. 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. Fig. 8 Installing Valve Cover 16. Insert valve cover over dowel pins. Ensure outlet fitting hole in valve cover is aligned with square mounting lug on housing. 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 lb. Use care not to cock flow control valve when installing. Do not force valve forward otherwise damage to housing may result. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver side air bag module connector. 5. Connect Rotunda Air Bag Simulator 105-00010 or equivalent to vehicle harness at top of steering wheel. 6. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. REACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute for backup power supply to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. Reconnect driver air bag module connector. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten nut and washer assemblies 4-6 Nm (36-53 lb-in). 4. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 5. Prove out system. Refer to System Prove Out Procedure under Testing and Inspection / Procedures / Diagnostic Strategies. WARNING: THE AIR BAG SIMULATOR(S) MUST BE REMOVED AND THE DRIVER SIDE AIR BAG MODULE RECONNECTED FOR THE SYSTEM TO BE REACTIVATED. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 6990 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Are center sensor and frame rail sensor connected and mounted to vehicle? ........................................................................................................... [ ] 2. Is right cowl side sensor connected and mounted to vehicle? ................................................................................................................................... [ ] 3. Is gray three-way connector at base of steering column connected? ........................................................................................................................ [ ] 4. Is air bag or air bag simulator connected? ...................................................................................... .......................................................................... [ ] 5. Is air bag diagnostic monitor connected? ........................................................................................ ......................................................................... [ ] 6. Is vehicle battery connected? .......................................................................................................... .......................................................................... [ ] Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 96231 > Nov > 96 > Steering Wheel - Clicking Noise Heard When Turning Steering Column Bearing: Customer Interest Steering Wheel - Clicking Noise Heard When Turning Article No. 96-23-1 11/04/96 ^ STEERING - "CLICKING" NOISE HEARD WHEN TURNING STEERING WHEEL ^ NOISE - "CLICKING" SOUND HEARD WHEN TURNING STEERING WHEEL FORD: 1990-91 CROWN VICTORIA, TAURUS LINCOLN-MERCURY: 1990-91 GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1991 CONTINENTAL LIGHT TRUCK: 1992-96 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES 1995-96 EXPLORER, RANGER, WINDSTAR This TSB article is being republished in its entirety to revise the procedure and parts needed. ISSUE: A "clicking" noise may be heard when turning the steering wheel. This condition may be caused by minor surface variations in the original stamped non-silver plated upper column bearings. ACTION: Install an Upper Steering Column Bearing Kit if noise occurs during Diagnosis procedure. Refer to the following Service Procedure for installation details. NOTE: THE CLICKING NOISE DOES NOT AFFECT STEERING OPERATION. DIAGNOSIS Before replacing the bearings, the following checks should be made: 1. Hold the steering wheel in the 3 and 9 o'clock positions and rock the wheel (without rotating it) about its center, checking for the clicking noise. 2. Repeat while holding the wheel in the 12 and 6 o'clock positions. SERVICE PROCEDURE If the noise does not occur with the above checks, the noise is due to another component such as the clockspring and this TSB article does not apply. If the noise does occur, install the Upper Steering Column Bearing Kit (F6AZ-3605-AA) which includes silver plated upper steering column bearings. Refer to Instruction Sheet 7162 provided in the Upper Steering Column Bearing Kit for replacement procedure. The Upper Steering Column Bearing Kit (F6AZ-3605-AA) contains one (1) each of the following items: ^ Steel Tolerance Ring ^ Steel Sleeve (Stamped) ^ Bearing Pre-Load Spring ^ Upper Bearing Snap Ring ^ Steering Wheel Attaching Bolt ^ Small Upper Bearing (Silver Plated) ^ Large Upper Bearing (Silver Plated) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 96231 > Nov > 96 > Steering Wheel - Clicking Noise Heard When Turning > Page 6999 ^ Instruction Sheet (I.S. 7162) PART NUMBER PART NAME F6AZ-3605-AA Upper Steering Column Bearing kit OTHER APPLICABLE ARTICLES: 89-25-3, 90-25-8, 91-3-1 SUPERSEDES: 92-12-3 920603 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991 Lincolns And 1992-96 Vehicles, Basic Warranty Coverage For All Other Vehicle Lines OPERATION DESCRIPTION TIME 962301A Install Steering Column 1.9 Hrs. Bearing Kit - 1990-91 Crown Victoria/Grand Marquis 962301B Install Steering Column 1.4 Hrs. Bearing Kit - 1990-91 Taurus (Manual Transmission) 962301C Install Steering Column 1.6 Hrs. Bearing Kit - 1990-91 Taurus/Sable (Automatic Transmission) 962301D Install Steering Column 1.7 Hrs. Bearing Kit - 1990-91 Mark VII 962301E Install Steering Column 1.8 Hrs. Bearing Kit - 1990-91 Town Car 962301F Install Steering Column 1.6 Hrs. Bearing Kit - 1991 Continental 962301G Install Steering Column 1.8 Hrs. Bearing Kit - 1995-96 Windstar (Without Tilt Wheel) 962301H Install Steering Column 1.9 Hrs. Bearing Kit - 1995-96 Windstar (With Tilt Wheel) 962301J Install Steering Column 1.8 Hrs. Bearing Kit - 1995-96 Ranger/Explorer (With Tilt Wheel) 962301K Install Steering Column 1.7 Hrs. Bearing Kit - 1995-96 Ranger/Explorer (Without Tilt Wheel) 962301L Install Steering Column 2.0 Hrs. Bearing Kit - 1992-96 Econoline (With SRS And Tilt Wheel) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > Customer Interest: > 96231 > Nov > 96 > Steering Wheel - Clicking Noise Heard When Turning > Page 7000 962301M Install Steering Column 1.9 Hrs. Bearing Kit - 1992-96 Econoline (With SRS And Without Tilt Wheel) 962301N Install Steering Column 1.8 Hrs. Bearing Kit - 1992-96 Econoline (Without SRS And With Tilt Wheel) 9623010 Install Steering Column 1.7 Hrs. Bearing Kit - 1992-96 Econoline (Without SRS Or Tilt Wheel) 962301P Install Steering Column 1.8 Hrs. Bearing Kit - 1992-96 F-150-350/Bronco (With SRS And Tilt Wheel) 962301Q Install Steering Column 1.7 Hrs. Bearing Kit - 1992-96 F-150-350/Bronco (With SRS And Without Tilt Wheel) 962301R Install Steering Column 1.7 Hrs. Bearing Kit - 1994-96 F-150-350/Bronco (Without SRS And With Tilt Wheel) 962301S Install Steering Column 1.6 Hrs. Bearing Kit - 1994-96 F-150-350/Bronco (Without SRS Or Tilt Wheel) 962301T Install Steering Column 1.7 Hrs. Bearing Kit - 1992-96 Aerostar DEALER CODING CONDITION BASIC PART NO. CODE 3517 56 OASIS CODES: 303000, 702000, 702300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 96231 > Nov > 96 > Steering Wheel - Clicking Noise Heard When Turning Steering Column Bearing: All Technical Service Bulletins Steering Wheel - Clicking Noise Heard When Turning Article No. 96-23-1 11/04/96 ^ STEERING - "CLICKING" NOISE HEARD WHEN TURNING STEERING WHEEL ^ NOISE - "CLICKING" SOUND HEARD WHEN TURNING STEERING WHEEL FORD: 1990-91 CROWN VICTORIA, TAURUS LINCOLN-MERCURY: 1990-91 GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1991 CONTINENTAL LIGHT TRUCK: 1992-96 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES 1995-96 EXPLORER, RANGER, WINDSTAR This TSB article is being republished in its entirety to revise the procedure and parts needed. ISSUE: A "clicking" noise may be heard when turning the steering wheel. This condition may be caused by minor surface variations in the original stamped non-silver plated upper column bearings. ACTION: Install an Upper Steering Column Bearing Kit if noise occurs during Diagnosis procedure. Refer to the following Service Procedure for installation details. NOTE: THE CLICKING NOISE DOES NOT AFFECT STEERING OPERATION. DIAGNOSIS Before replacing the bearings, the following checks should be made: 1. Hold the steering wheel in the 3 and 9 o'clock positions and rock the wheel (without rotating it) about its center, checking for the clicking noise. 2. Repeat while holding the wheel in the 12 and 6 o'clock positions. SERVICE PROCEDURE If the noise does not occur with the above checks, the noise is due to another component such as the clockspring and this TSB article does not apply. If the noise does occur, install the Upper Steering Column Bearing Kit (F6AZ-3605-AA) which includes silver plated upper steering column bearings. Refer to Instruction Sheet 7162 provided in the Upper Steering Column Bearing Kit for replacement procedure. The Upper Steering Column Bearing Kit (F6AZ-3605-AA) contains one (1) each of the following items: ^ Steel Tolerance Ring ^ Steel Sleeve (Stamped) ^ Bearing Pre-Load Spring ^ Upper Bearing Snap Ring ^ Steering Wheel Attaching Bolt ^ Small Upper Bearing (Silver Plated) ^ Large Upper Bearing (Silver Plated) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 96231 > Nov > 96 > Steering Wheel - Clicking Noise Heard When Turning > Page 7006 ^ Instruction Sheet (I.S. 7162) PART NUMBER PART NAME F6AZ-3605-AA Upper Steering Column Bearing kit OTHER APPLICABLE ARTICLES: 89-25-3, 90-25-8, 91-3-1 SUPERSEDES: 92-12-3 920603 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991 Lincolns And 1992-96 Vehicles, Basic Warranty Coverage For All Other Vehicle Lines OPERATION DESCRIPTION TIME 962301A Install Steering Column 1.9 Hrs. Bearing Kit - 1990-91 Crown Victoria/Grand Marquis 962301B Install Steering Column 1.4 Hrs. Bearing Kit - 1990-91 Taurus (Manual Transmission) 962301C Install Steering Column 1.6 Hrs. Bearing Kit - 1990-91 Taurus/Sable (Automatic Transmission) 962301D Install Steering Column 1.7 Hrs. Bearing Kit - 1990-91 Mark VII 962301E Install Steering Column 1.8 Hrs. Bearing Kit - 1990-91 Town Car 962301F Install Steering Column 1.6 Hrs. Bearing Kit - 1991 Continental 962301G Install Steering Column 1.8 Hrs. Bearing Kit - 1995-96 Windstar (Without Tilt Wheel) 962301H Install Steering Column 1.9 Hrs. Bearing Kit - 1995-96 Windstar (With Tilt Wheel) 962301J Install Steering Column 1.8 Hrs. Bearing Kit - 1995-96 Ranger/Explorer (With Tilt Wheel) 962301K Install Steering Column 1.7 Hrs. Bearing Kit - 1995-96 Ranger/Explorer (Without Tilt Wheel) 962301L Install Steering Column 2.0 Hrs. Bearing Kit - 1992-96 Econoline (With SRS And Tilt Wheel) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 96231 > Nov > 96 > Steering Wheel - Clicking Noise Heard When Turning > Page 7007 962301M Install Steering Column 1.9 Hrs. Bearing Kit - 1992-96 Econoline (With SRS And Without Tilt Wheel) 962301N Install Steering Column 1.8 Hrs. Bearing Kit - 1992-96 Econoline (Without SRS And With Tilt Wheel) 9623010 Install Steering Column 1.7 Hrs. Bearing Kit - 1992-96 Econoline (Without SRS Or Tilt Wheel) 962301P Install Steering Column 1.8 Hrs. Bearing Kit - 1992-96 F-150-350/Bronco (With SRS And Tilt Wheel) 962301Q Install Steering Column 1.7 Hrs. Bearing Kit - 1992-96 F-150-350/Bronco (With SRS And Without Tilt Wheel) 962301R Install Steering Column 1.7 Hrs. Bearing Kit - 1994-96 F-150-350/Bronco (Without SRS And With Tilt Wheel) 962301S Install Steering Column 1.6 Hrs. Bearing Kit - 1994-96 F-150-350/Bronco (Without SRS Or Tilt Wheel) 962301T Install Steering Column 1.7 Hrs. Bearing Kit - 1992-96 Aerostar DEALER CODING CONDITION BASIC PART NO. CODE 3517 56 OASIS CODES: 303000, 702000, 702300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Bearing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Column Bearing: > 95212 > Jan > 95 > A/T - E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation Steering Gear: Description and Operation Fig. 1 Ford Integral Power Steering Gear The Ford XR-50 power steering unit is a torsion bar type of hydraulic-assisted system. This system furnishes power to reduce the amount of turning effort required at the steering wheel. It also reduces road shock and vibrations. Fig. 2 Ball And Nut Housing The unit includes a worm and one piece rack-piston which is meshed to the gear teeth on the steering sector shaft. The unit also includes a hydraulic valve, actuator, input shaft and torsion bar assembly which are mounted on the end of the worm shaft and operated by a twisting action of the torsion bar. This rotary valve type gear, uses a one piece rotary valve and sleeve assembly. Therefore no centering shims are used and no adjustment is possible. This makes possible internal fluid passages between valve and cylinder, thus eliminating all external lines and hoses except the pressure and return hoses between pump and gear. The power cylinder is an integral part of the gear housing. The piston is double acting in that fluid pressure may be applied to either side of the piston. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Rotary Valve Centering Inspection Steering Gear: Adjustments Rotary Valve Centering Inspection 1. Install a 2000 psi pressure gauge in pressure line between pump outlet port and steering gear inlet port. Make sure valve on gauge is in fully open position. 2. Check fluid level in reservoir and replenish as required. 3. Start engine and cycle steering wheel from stop-to-stop to bring steering lubricant up to normal operating temperature. Stop engine and recheck reservoir. Add fluid as necessary. 4. With engine running at a fast idle speed (1000 RPM) and steering wheel centered, attach an inch pound torque wrench to steering wheel retaining nut. Apply sufficient torque to wrench in each direction (either side of center) to get a gauge reading of 250 psi. 5. Torque reading should be the same in both directions. If difference between readings exceeds 6 in lb, remove steering gear from vehicle and replace shaft and control assembly. The "out-of-vehicle" procedure for centering check is the same as for the "in-vehicle" except torque and simultaneous pressure reading must be made at right and left stops instead of either side of center. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Rotary Valve Centering Inspection > Page 7023 Steering Gear: Adjustments Sector and Rack Teeth Lash NOTE: Preload (thrust bearing adjustment) and worm-to-rack preload cannot be changed in service. The only adjustment that can be performed is the total overcenter position load to eliminate excessive lash between sector and rack teeth. 1. Disconnect pitman arm from sector shaft. 2. Disconnect fluid return line at reservoir and cap reservoir return line pipe. 3. Place end of return line in a clean container and cycle steering wheel in both directions as required to discharge fluid from gear. 4. Carefully remove airbag assembly from steering wheel hub, then turn steering wheel 45 degrees from right stop. 5. Using an inch pound torque wrench on steering wheel nut, determine torque required to rotate shaft slowly through approximately 1/8 turn from 45 degrees position. 6. Turn steering gear back to center, then determine torque required to rotate shaft back and forth across center position. 7. Adjust if meshload required to rotate shaft back and forth across center position is less than 7 in lb greater than the force required to rotate shaft from 45 degrees to stop. Loosen adjusting nut and turn adjusting screw until reading is 10-14 in lb greater than torque measured 45 degrees from stop. Hold screw in place, then tighten locknut. 8. Check readings, then install pitman arm and steering wheel cover. 9. Connect fluid return line and replenish reservoir. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement Steering Gear: Service and Repair Replacement Gear Housing Replace Fig. 5 Steering Gear Housing 1. Remove snap ring from lower end of housing. 2. Remove dust seal using impact hammer tools Nos. T58L-101-A and T59L-100-B, or equivalents. 3. Remove and discard pressure seal in same manner as dust seal. 4. Apply suitable lubricant to new pressure and dust seal. 5. Position dust seal on seal replacer tool No. T77L-3576-A, or equivalent, so raised lip of seal faces tool. 6. Position pressure seal on tool with seal lip away from tool and flat side of seal contacting flat side of dust seal. 7. Insert seal driver tool into sector shaft bore and drive tool in until seals clear snap ring groove. To ensure proper sealing, seals must not be bottomed against bearing. 8. Install snap ring in groove in housing. Piston & Ball Nut Fig. 2 Ball And Nut Housing 1. Remove Teflon(R) ring and O-ring from piston and ball nut. 2. Dip a new O-ring in gear lube and install on piston and ball nut. 3. Install new Teflon(R) ring on piston and ball nut, being careful not to stretch it any more than necessary. Valve Housing Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7026 Fig. 4 Valve Housing 1. Remove dust seal and snap ring. 2. Invert housing and from opposite seal end, gently tap bearing and seal out of housing. Exercise care when inserting and removing tool to prevent damage to valve bore in housing. 3. Remove oil inlet and outlet tube seats with "EZ-Out" if damaged. 4. Coat tube seats with petroleum jelly and position them in housing. Install and tighten tube nuts to press seats to proper location. 5. Coat bearing and seal surface in housing with a film of petroleum jelly. 6. Position bearing in valve housing. Seat bearing in housing with bearing installation tool No. T65P-3524-A1, or equivalent, ensuring that bearing rotates freely. 7. Dip new oil seal in gear lube. Then position seal facing outward. Drive seal into housing until outer edge of seal does not quite clear snap ring. 8. Place snap ring in housing. Then drive on ring with bearing remover tool No. T65P-3524-A1, or equivalent, until snap ring seats in its groove to locate seal properly. 9. Place dust seal in housing with dished side (rubber side) facing out. Drive dust seal in place so that it is located behind undercut in input shaft when it is installed. Worm & Valve Sleeve Fig. 2 Ball And Nut Housing 1. Remove valve sleeve rings from sleeve by inserting blade of a small pocket knife carefully under them and cutting them off, without scratching valve sleeve. 2. With worm end of the worm and valve sleeve assembly mounted into a soft jawed vise, install mandrel tool No. T75L-3517-A1, or equivalent, over sleeve and slide one valve sleeve ring over tool. 3. Slide pusher tool No. T75L-3517-A2, or equivalent, over mandrel, then rapidly push down on pusher tool, forcing the ring down the ramp and into the fourth groove of the valve sleeve. Repeat this step three more times, each time adding one of the spacer tools No. T75L-3517-A3, or equivalent, under mandrel tool. Adding spacers each time will align mandrel tool with next groove of valve sleeve. 4. After installing all four valve sleeve rings, apply a light coat of gear lubricant to sleeve and rings. 5. Slowly install sizing tube tool No. T75L-3517-A4, or equivalent, over sleeve valve end of worm shaft and onto valve sleeve rings. Ensure rings turn freely in grooves. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7027 Steering Gear: Service and Repair Disassembly and Assembly DISASSEMBLE NOTE: Do not use solvent on seals. 1. Using a clean workbench and tools, thoroughly clean the exterior of the gear with solvent. Drain off excess hydraulic fluid, it necessary. 2. Handle all parts carefully to avoid nicks, burrs, scratches and dirt. Steering Gear SPECIAL SERVICE TOOL(S) REQUIRED 1. Hold steering gear over drain pan in an inverted position and cycle input shaft six times to drain remaining fluid from gear. NOTE: The indexing flat on the power steering gear input shaft and control should be facing downward. 2. Secure the steering gear in a soft-jawed vise. 3. Turn the power steering gear input shaft and control to either stop, then turn it back two turns to center the steering gear. 4. Remove bolts to the steering gear housing end cover (3568). 5. Remove locknut and brass thrust washer from adjusting screw. 6. Turn input shaft to either stop, then turn it back approximately two turns to center gear. 7. Remove sector shaft cover bolts, brake line bracket and identification tag, if applicable. 8. Tap lower end of sector shaft with a soft-faced hammer to loosen it, then lift cover and shaft from housing as a unit. Discard O-ring. NOTE: The following step is required only when it is necessary to remove steering gear sector shaft from the sector assembly. 9. Turn sector shaft cover counterclockwise off adjuster screw. 10. Remove four valve housing attaching bolts. Lift valve housing from gear housing while holding piston to prevent it from rotating off worm shaft. Remove valve housing and lube passage O-rings and discard. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7028 NOTE: If valve housing or the front suspension steering ball stud dust seals (3332) are to be replaced, proceed to Step 14. If steering gear sector shaft housing oil seal (3591) are to be replaced go to steering gear housing section Disassembly and Assembly. Steering gear worm ball (3647) need to be removed if front suspension steering ball stud dust seal are to be replaced. 11. With the piston held so the steering gear ball return guide (3523) faces up, remove the ball guide clamp screws and steering gear ball return guide clamp (3544). 12. With a finger over the opening in the steering gear ball return guide, turn the piston so the steering gear ball return guide faces down over a clean container. Let the steering gear ball return guide drop into the container. 13. Rotate the power steering gear input shaft and control from stop to stop until all balls fall from the piston into the container. The steering gear input worm gear and rack can then be removed from the piston. Inspect the piston bore to make sure all steering gear worm ball have been removed. 14. Install the steering gear input worm gear and rack in the Bench Mounted Holding Fixture T57L-500-B and loosen the Allen head race locknut screw from the valve housing. 15. Remove the steering gear worm thrust bearing lock nut (3707) using Adjuster and Locknut Wrench T66P-3553-B and Valve Housing to Piston Spacer T66P-3553-C. 16. Carefully slide the power steering gear input shaft and control, steering gear input worm gear and rack out of the valve housing. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7029 REMOVING WORM BEARING RACE LOCKNUT 17. Stand valve body and piston on end with piston end down. Rotate input shaft counterclockwise out of piston, allowing balls to drop into piston. 18. Place a cloth over open end of piston and turn it upside down to remove balls. Fig. 2 Ball And Nut Housing 19. Remove ball guide clamp screws from ball nut and remove clamp and guides. 20. Hold valve body in a fixture and loosen allen head race nut screw from valve housing and remove worm bearing race nut. 21. Carefully slide input shaft, worm and valve out of valve housing. ASSEMBLE 1. Mount the steering gear input worm gear and rack in the Bench Mounted Holding Fixture T57L-500-B with the flanged end up. 2. Apply suitable power steering fluid to valve sleeve rings, then install worm and valve in housing. 3. Install race nut in housing and torque to 55-90 ft lb. 4. Install race nut setscrew and torque to 15-25 in lb. 5. Place piston on bench with ball guide holes facing up. Insert worm shaft into piston so that first groove is in alignment with hole nearest center of piston. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Replacement > Page 7030 Fig. 3 Installing Piston On Worm Shaft 6. Place ball guide into piston. Place 27 to 29 balls in guide, (depending on piston design), turning worm clockwise (viewed from input end of shaft). If all balls have not been fed into guide upon reaching right stop, rotate input shaft in one direction and then in the other while installing remaining balls. After balls have been installed, do not rotate input shaft or piston more than 3 and 1/2 turns off the right stop to prevent balls from falling out of circuit. 7. Secure guides to ball nut with clamp. Torque clamp screws to 42-70 in lb. 8. Position new lube passage O-ring in counterbore of gear housing. 9. Apply petroleum jelly to Teflon(R) seal. 10. Place a new O-ring on valve housing. 11. Slide piston and valve into gear housing, being careful not to damage Teflon(R) seal. 12. Align lube passage in valve housing with one in gear housing, and install but do not tighten attaching bolts at this time. 13. Rotate ball nut so that teeth are in same plane as sector teeth. Torque four valve housing attaching bolts to 30-45 ft lb. 14. Position sector shaft cover O-ring in gear housing. Turn input shaft as required to center piston. 15. Apply petroleum jelly to sector shaft journal, then position sector shaft and cover into gear housing. Install brake line bracket, identification tag and air conditioner line mounting bracket (if so equipped) and sector shaft cover bolts, torquing them to 55-70 ft lb. 16. Attach an inch pound torque wrench to input shaft and adjust mesh load. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest: > 9697 > Apr > 96 > Steering Wheel - Squeaks While Turning Steering Wheel: Customer Interest Steering Wheel - Squeaks While Turning Article No. 96-9-7 04/22/96 STEERING - STEERING WHEEL "SQUEAK" WHILE TURNING - VEHICLES WITHOUT AIR BAG - 1993-94 OVER 8500 GVW AND 1995 E-350 STRIPPED CHASSIS AND CUTAWAY LIGHT TRUCK: 1993-94 ECONOLINE 1995 E-350 ISSUE: A "squeak" noise while turning the steering wheel may occur on some vehicles. This may be caused by contact between the clockspring's rotor and housing within the steering wheel assembly. ACTION: Replace the clockspring assembly with a brush assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE REMOVAL 1. Center front wheels to the straight ahead position. 2. Disconnect the battery ground cable. 3. Unsnap the steering wheel pad horn switch from the steering wheel by grasping the sides of the steering wheel pad horn switch and pulling toward yourself (Figure 1). 4. Disconnect the horn/speed control wire harness connector from the contact assembly. Remove and discard the steering wheel pad horn switch from the steering wheel. Keep the retaining screw (390345-S36 if necessary to replace), it will be used during the installation process. 5. Remove the steering wheel retaining bolt. 6. Install Steering Wheel Puller (T67L-3600-A) and remove steering wheel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest: > 9697 > Apr > 96 > Steering Wheel - Squeaks While Turning > Page 7039 7. Remove the clockspring assembly and discard. INSTALLATION 1. Make sure the vehicle's front wheels are in the straight ahead position. 2. Install new wiring with new brush assembly (-90899-) by aligning the bolt on the brush to the steering column and connect the ignition cylinder, PRNDL label, and wiring harness connectors (-14A200-). Torque the retaining screw to 2-3 N.m (1.5-2.2 lb-ft) (Figure 2). 3. Position the new steering wheel (F6TZ-3600-AAA) on the steering shaft so the alignment marks are aligned. 4. Install a new steering wheel retaining bolt (N804385-S100) and tighten to 31-44 N.m (23-32 lb-ft). 5. Connect steering wheel pad horn switch speed control wire harness (-13A805-) to brush assembly connector. 6. Position steering wheel pad horn switch over steering wheel and snap into place. 7. Reconnect the battery ground cable. NOTE: WHEN THE BATTERY HAS BEEN DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE POWERTRAIN CONTROL MODULE (PCM) RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16km (10 MILES) OR MORE FOR PCM TO RELEARN THE STRATEGY. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest: > 9697 > Apr > 96 > Steering Wheel - Squeaks While Turning > Page 7040 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960907A Replace Clockspring With 0.5 Hr. Brush Assembly DEALER CODING CONDITION BASIC PART NO. CODE 13806 79 OASIS CODES: 107000, 203000, 303000, 702000, 702300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9697 > Apr > 96 > Steering Wheel - Squeaks While Turning Steering Wheel: All Technical Service Bulletins Steering Wheel - Squeaks While Turning Article No. 96-9-7 04/22/96 STEERING - STEERING WHEEL "SQUEAK" WHILE TURNING - VEHICLES WITHOUT AIR BAG - 1993-94 OVER 8500 GVW AND 1995 E-350 STRIPPED CHASSIS AND CUTAWAY LIGHT TRUCK: 1993-94 ECONOLINE 1995 E-350 ISSUE: A "squeak" noise while turning the steering wheel may occur on some vehicles. This may be caused by contact between the clockspring's rotor and housing within the steering wheel assembly. ACTION: Replace the clockspring assembly with a brush assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE REMOVAL 1. Center front wheels to the straight ahead position. 2. Disconnect the battery ground cable. 3. Unsnap the steering wheel pad horn switch from the steering wheel by grasping the sides of the steering wheel pad horn switch and pulling toward yourself (Figure 1). 4. Disconnect the horn/speed control wire harness connector from the contact assembly. Remove and discard the steering wheel pad horn switch from the steering wheel. Keep the retaining screw (390345-S36 if necessary to replace), it will be used during the installation process. 5. Remove the steering wheel retaining bolt. 6. Install Steering Wheel Puller (T67L-3600-A) and remove steering wheel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9697 > Apr > 96 > Steering Wheel - Squeaks While Turning > Page 7046 7. Remove the clockspring assembly and discard. INSTALLATION 1. Make sure the vehicle's front wheels are in the straight ahead position. 2. Install new wiring with new brush assembly (-90899-) by aligning the bolt on the brush to the steering column and connect the ignition cylinder, PRNDL label, and wiring harness connectors (-14A200-). Torque the retaining screw to 2-3 N.m (1.5-2.2 lb-ft) (Figure 2). 3. Position the new steering wheel (F6TZ-3600-AAA) on the steering shaft so the alignment marks are aligned. 4. Install a new steering wheel retaining bolt (N804385-S100) and tighten to 31-44 N.m (23-32 lb-ft). 5. Connect steering wheel pad horn switch speed control wire harness (-13A805-) to brush assembly connector. 6. Position steering wheel pad horn switch over steering wheel and snap into place. 7. Reconnect the battery ground cable. NOTE: WHEN THE BATTERY HAS BEEN DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE POWERTRAIN CONTROL MODULE (PCM) RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16km (10 MILES) OR MORE FOR PCM TO RELEARN THE STRATEGY. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9697 > Apr > 96 > Steering Wheel - Squeaks While Turning > Page 7047 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960907A Replace Clockspring With 0.5 Hr. Brush Assembly DEALER CODING CONDITION BASIC PART NO. CODE 13806 79 OASIS CODES: 107000, 203000, 303000, 702000, 702300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Wheel: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake ON/OFF Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Wheel: > NHTSA 06V286000 > Jul > 06 > Recall 06V286000: Cruise Control Switch Fire Hazard Brake ON/OFF Switch: All Technical Service Bulletins Recall 06V286000: Cruise Control Switch Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/E450 1996-2002 Ford/Econoline 1994-1996 Ford/Excursion 2000-2002 Ford/Explorer 1998 Ford/F250 1994-2002 Ford/F350 1994-2002 Ford/F450 1994-2002 Ford/F550 1994-2002 Ford/Mountaineer 1998 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 06V286000 MFG'S REPORT DATE: July 27, 2006 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 1200000 SUMMARY: On certain trucks equipped with speed control, gasoline or natural gas engines, the speed control deactivation switch may overheat. CONSEQUENCE: Overheat could result in smoke, or burn and in an underhood fire. REMEDY: Dealers will install a fused wiring harness into the speed control system free of charge. The recall is expected to begin on August 7, 2006. Owners may contact Ford at 1-866-436-7332. NOTES: Ford recall No. 05S28. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > With Airbag Steering Wheel: Service and Repair With Airbag 1. Place front wheels in straight ahead position. 2. Remove air bag module to steering wheel attaching nuts. 3. Disconnect air bag electrical connector, then remove air bag module. 4. Disconnect horn/speed control harness electrical connector from steering wheel. 5. Remove steering wheel attaching bolt. 6. Using steering wheel puller tool No. T67L-3600-A, or equivalent, remove steering wheel. 7. Reverse procedure to install. torque steering wheel attaching bolt to 23-33 ft lb torque air bag module attaching nuts to 36-48 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > With Airbag > Page 7068 Steering Wheel: Service and Repair Without Airbag 1. Position the wheels in a straight-ahead position. 2. Disconnect battery ground cable. 3. Unsnap the steering wheel pad horn switch from the steering wheel by grasping the sides of the steering wheel pad horn switch and pulling toward yourself. 4. Disconnect the horn/speed control wire harness connector from the air bag sliding contact and remove the steering wheel pad horn switch from the steering wheel. 5. Remove the steering wheel retaining nut. 6. Using steering wheel puller tool No. T67L-3600-A, or equivalent, remove steering wheel from shaft. 7. Reverse procedure to install. Torque steering wheel attaching bolt to 23-33 ft lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 Twin I-beam Front Axle These vehicles use two I-beam type 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 pivot 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. 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Customer Interest: > 95206 > Oct > 95 > Upper Ball Joints - Clunking Noise/Wear Ball Joint: Customer Interest Upper Ball Joints - Clunking Noise/Wear Article No. 95-20-6 10/11/95 ^ BALL JOINTS - UPPER - EARLY WEAR OUT DUE TO MOISTURE AND CONTAMINATION ENTRY ^ NOISE - "CLUNK" FROM UPPER BALL JOINTS - EARLY WEAR OUT DUE TO MOISTURE AND CONTAMINATION ENTRY LIGHT TRUCK: 1992-95 ECONOLINE This TSB is being republished in its entirety to include the 1995 model year and the latest level parts. ISSUE: Upper ball joints may have early wear on some vehicles. This may be due to entry of moisture and contamination into the ball joint. ACTION: Replace the worn ball joint(s) with a new integral seal-type ball joint which has improved sealing to reduce entry of moisture and contamination. Refer to the 1995 Econoline Service Manual Page 04-01-8 for service details. CAUTION: DO NOT DAMAGE THE LOWER BALL JOINT WHEN REPLACING THE UPPER BALL JOINT. PART NUMBER PART NAME F5UZ-3049-A Upper Ball Joint OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-11-14 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952006AT Replace Both Upper Ball 3.3 Hrs. Joints (Includes Check And Correct Alignment) - E-150 952006A Replace One Upper Ball 2.2 Hrs. Joint (Includes Check And Correct Alignment) - E-150 952006BT Replace Both Upper Ball 3.8 Hrs. Joints (Includes Check And Correct Alignment) - E-250-350 952006B Replace One Upper Ball 2.4 Hrs. Joint (Includes Check And Correct Alignment) - E-250-350 DEALER CODING CONDITION BASIC PART NO. CODE 3049 30 OASIS CODES: 304000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 99-14-1 > Jul > 99 > Ball Joint - Proper Inspection Procedure Ball Joint: All Technical Service Bulletins Ball Joint - Proper Inspection Procedure Article No. 99-14-1 07/12/99 BALL JOINT - PROPER INSPECTION PROCEDURE FORD: 1992-1999 ECONOLINE ISSUE A high number of ball joints are being replaced as the result of routine inspections or of complaints of tire wear and loose feelings in the steering system. Most of these parts are within specification and did not need replacement. There is a misunderstanding about how an Econoline/E-Series ball joint should feel and about how much movement is acceptable. ACTION Use proper inspection procedures and understand the acceptable amounts of movement within the ball joint. This action helps to avoid unnecessary replacement of ball joints at either customer or Ford Motor Company expense. Refer to the following Service Procedure for correct ball joint inspection details. SERVICE PROCEDURE NOTE DO NOT REPLACE SUSPENSION COMPONENTS THAT ARE WITHIN SPECIFICATION. Inspect Econoline/E-Series ball joints by lifting the vehicle and supporting the front axles on jack stands. Refer to the 1999 Econoline Workshop Manual, Section 100-02, for proper lifting techniques. Prior to performing any inspection of the ball joints, inspect the front wheel bearings for proper adjustment as follows: 1. Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. 2. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, adjust the front wheel bearing. For additional information, refer to the Workshop Manual, Section 206-03. NOTE SKIPPING INSPECTION OF THE WHEEL BEARINGS MAY RESULT IN FALSE READINGS ON BALL JOINT MOVEMENT. THIS MAY LEAD TO UNNECESSARY PARTS REPLACEMENT. LOWER BALL JOINT Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 99-14-1 > Jul > 99 > Ball Joint - Proper Inspection Procedure > Page 7086 1. Once wheel bearing inspection/adjustment is complete, have an assistant push and pull on the bottom of the tire (Figure 1). 2. Measure the amount of lateral lash AT THE BALL JOINT (Figure 1, View 1). Do Not Replace ball joint unless lateral lash movement is at or above 0.8 mm (1/32") AT THE BALL JOINT. Lateral lash of 0.8 mm (1/32") AT THE BALL JOINT will give a measurement of up to 4 mm (5/32") of movement at the bottom outer diameter of the tire (Figure 1, View 2). UPPER BALL JOINT 1. Once wheel bearing inspection/adjustment is complete, have an assistant push and pull on the top of the tire (Figure 2). 2. Measure the amount of lateral lash AT THE BALL JOINT (Figure 2, View 1). Do Not Replace ball joint unless lateral lash movement is at or above 0.8 mm (1/32") AT THE BALL JOINT. Lateral lash of 0.8 mm (1/32") AT THE BALL JOINT will give a measurement of up to 4 mm (5/32") of movement at the top outer diameter of the tire (Figure 2, View 2). VERTICAL END PLAY BOTH BALL JOINTS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 99-14-1 > Jul > 99 > Ball Joint - Proper Inspection Procedure > Page 7087 Econoline/E-Series ball joints have vertical end play. AT THE BALL JOINT (upper or lower), measure the amount of vertical end play. Do Not Replace the ball joint unless the vertical end play is at or above 2.3 mm (3/32") AT THE BALL JOINT (Figure 3). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 303000, 304000, 306000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 95206 > Oct > 95 > Upper Ball Joints - Clunking Noise/Wear Ball Joint: All Technical Service Bulletins Upper Ball Joints - Clunking Noise/Wear Article No. 95-20-6 10/11/95 ^ BALL JOINTS - UPPER - EARLY WEAR OUT DUE TO MOISTURE AND CONTAMINATION ENTRY ^ NOISE - "CLUNK" FROM UPPER BALL JOINTS - EARLY WEAR OUT DUE TO MOISTURE AND CONTAMINATION ENTRY LIGHT TRUCK: 1992-95 ECONOLINE This TSB is being republished in its entirety to include the 1995 model year and the latest level parts. ISSUE: Upper ball joints may have early wear on some vehicles. This may be due to entry of moisture and contamination into the ball joint. ACTION: Replace the worn ball joint(s) with a new integral seal-type ball joint which has improved sealing to reduce entry of moisture and contamination. Refer to the 1995 Econoline Service Manual Page 04-01-8 for service details. CAUTION: DO NOT DAMAGE THE LOWER BALL JOINT WHEN REPLACING THE UPPER BALL JOINT. PART NUMBER PART NAME F5UZ-3049-A Upper Ball Joint OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-11-14 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952006AT Replace Both Upper Ball 3.3 Hrs. Joints (Includes Check And Correct Alignment) - E-150 952006A Replace One Upper Ball 2.2 Hrs. Joint (Includes Check And Correct Alignment) - E-150 952006BT Replace Both Upper Ball 3.8 Hrs. Joints (Includes Check And Correct Alignment) - E-250-350 952006B Replace One Upper Ball 2.4 Hrs. Joint (Includes Check And Correct Alignment) - E-250-350 DEALER CODING CONDITION BASIC PART NO. CODE 3049 30 OASIS CODES: 304000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Joint: > 99-14-1 > Jul > 99 > Ball Joint - Proper Inspection Procedure Ball Joint: All Technical Service Bulletins Ball Joint - Proper Inspection Procedure Article No. 99-14-1 07/12/99 BALL JOINT - PROPER INSPECTION PROCEDURE FORD: 1992-1999 ECONOLINE ISSUE A high number of ball joints are being replaced as the result of routine inspections or of complaints of tire wear and loose feelings in the steering system. Most of these parts are within specification and did not need replacement. There is a misunderstanding about how an Econoline/E-Series ball joint should feel and about how much movement is acceptable. ACTION Use proper inspection procedures and understand the acceptable amounts of movement within the ball joint. This action helps to avoid unnecessary replacement of ball joints at either customer or Ford Motor Company expense. Refer to the following Service Procedure for correct ball joint inspection details. SERVICE PROCEDURE NOTE DO NOT REPLACE SUSPENSION COMPONENTS THAT ARE WITHIN SPECIFICATION. Inspect Econoline/E-Series ball joints by lifting the vehicle and supporting the front axles on jack stands. Refer to the 1999 Econoline Workshop Manual, Section 100-02, for proper lifting techniques. Prior to performing any inspection of the ball joints, inspect the front wheel bearings for proper adjustment as follows: 1. Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. 2. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, adjust the front wheel bearing. For additional information, refer to the Workshop Manual, Section 206-03. NOTE SKIPPING INSPECTION OF THE WHEEL BEARINGS MAY RESULT IN FALSE READINGS ON BALL JOINT MOVEMENT. THIS MAY LEAD TO UNNECESSARY PARTS REPLACEMENT. LOWER BALL JOINT Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Joint: > 99-14-1 > Jul > 99 > Ball Joint - Proper Inspection Procedure > Page 7097 1. Once wheel bearing inspection/adjustment is complete, have an assistant push and pull on the bottom of the tire (Figure 1). 2. Measure the amount of lateral lash AT THE BALL JOINT (Figure 1, View 1). Do Not Replace ball joint unless lateral lash movement is at or above 0.8 mm (1/32") AT THE BALL JOINT. Lateral lash of 0.8 mm (1/32") AT THE BALL JOINT will give a measurement of up to 4 mm (5/32") of movement at the bottom outer diameter of the tire (Figure 1, View 2). UPPER BALL JOINT 1. Once wheel bearing inspection/adjustment is complete, have an assistant push and pull on the top of the tire (Figure 2). 2. Measure the amount of lateral lash AT THE BALL JOINT (Figure 2, View 1). Do Not Replace ball joint unless lateral lash movement is at or above 0.8 mm (1/32") AT THE BALL JOINT. Lateral lash of 0.8 mm (1/32") AT THE BALL JOINT will give a measurement of up to 4 mm (5/32") of movement at the top outer diameter of the tire (Figure 2, View 2). VERTICAL END PLAY BOTH BALL JOINTS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ball Joint: > 99-14-1 > Jul > 99 > Ball Joint - Proper Inspection Procedure > Page 7098 Econoline/E-Series ball joints have vertical end play. AT THE BALL JOINT (upper or lower), measure the amount of vertical end play. Do Not Replace the ball joint unless the vertical end play is at or above 2.3 mm (3/32") AT THE BALL JOINT (Figure 3). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 303000, 304000, 306000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint, Lower Ball Joint: Testing and Inspection Ball Joint, Lower 1. Adjust front wheel bearings. Fig. 13 Checking Lower Ball Joint For Ware 2. Check lower ball joint by grasping lower edge of tire and moving wheel in and out while observing lower spindle arm and lower portion of axle jaw. If movement exceeds 1/32 inch, Fig. 8, the lower ball joint must be replaced. 3. Check upper ball joint by grasping upper edge of tire and moving wheel in and out. If movement exceeds 1/32 inch, the upper ball joint must be replaced. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint, Lower > Page 7101 Ball Joint: Testing and Inspection Ball Joint, Upper 1. Adjust front wheel bearings as outlined under Wheel Bearing. Fig. 13 Checking Lower Ball Joint For Ware 2. Check lower ball joint by grasping lower edge of tire and moving wheel in and out while observing lower spindle arm and lower portion of axle jaw. If movement exceeds 1/32 inch, Fig. 8, the lower ball joint must be replaced. 3. Check upper ball joint by grasping upper edge of tire and moving wheel in and out. If movement exceeds 1/32 inch, the upper ball joint must be replaced. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower Ball Joint: Service and Repair Ball Joint, Lower Removal 1. Remove the front wheel spindle and ball joint assembly from the axle. NOTE: Lower ball joint must be removed first. 2. Install the front wheel spindle in a vise and remove the snap ring from the lower ball joint. 3. Remove the lower ball joint from the front wheel spindle. Use U-Joint Tool and Receiver Cup (part of Ball Joint Adapter Set). 4. Turn the forcing screw CLOCKWISE until the ball joint is removed from the front wheel spindle. CAUTION: Do not heat the ball joint or the front wheel spindle to aid in removal. 5. Assemble U-Joint Tool and cup on the upper ball joint, and turn forcing screw CLOCKWISE until ball joint is removed from the front wheel spindle. Installation CAUTION: Do not heat the ball joint or axle to aid in installation. NOTE: Upper ball joint must be installed into the front wheel spindle FIRST. NOTE: Individual ball joint tools are included in Ball Joint Adapter Set or equivalent. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 7104 1. To install the upper ball joint, assemble C-Frame assembly, Ball Joint Receiver Cup and Adaptors or equivalents inside Installation Cup or equivalent in position on the front wheel spindle. 2. Turn forcing screw CLOCKWISE until ball joint is seated. 3. To install the lower ball joint, assemble the C-frame in position on the front wheel spindle and repeat Step 1. 4. Install the snap ring onto the ball joint. 5. Install the spindle and ball joint assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 7105 Ball Joint: Service and Repair Ball Joint, Upper Removal 1. Remove the front wheel spindle and ball joint assembly from the axle. NOTE: Lower ball joint must be removed first. 2. Install the front wheel spindle in a vise and remove the snap ring from the lower ball joint. 3. Remove the lower ball joint from the front wheel spindle. Use U-Joint Tool and Receiver Cup (part of Ball Joint Adapter Set). 4. Turn the forcing screw CLOCKWISE until the ball joint is removed from the front wheel spindle. CAUTION: Do not heat the ball joint or the front wheel spindle to aid in removal. 5. Assemble U-Joint Tool and cup on the upper ball joint, and turn forcing screw CLOCKWISE until ball joint is removed from the front wheel spindle. Installation CAUTION: Do not heat the ball joint or axle to aid in installation. NOTE: Upper ball joint must be installed into the front wheel spindle FIRST. NOTE: Individual ball joint tools are included in Ball Joint Adapter Set or equivalent. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 7106 1. To install the upper ball joint, assemble C-Frame assembly, Ball Joint Receiver Cup and Adaptors or equivalents inside Installation Cup or equivalent in position on the front wheel spindle. 2. Turn forcing screw CLOCKWISE until ball joint is seated. 3. To install the lower ball joint, assemble the C-frame in position on the front wheel spindle and repeat Step 1. 4. Install the snap ring onto the ball joint. 5. Install the spindle and ball joint assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Removal 1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the disc brake caliper from the rotor and wire it out of the way. 4. Remove the dust cap, cotter pin, nut retainer, nut, washer, and front wheel bearing. 5. Remove the rotor from the front wheel spindle. 6. Remove bearing cone and roller and wheel hub grease seal. Discard the seal. 7. Remove front disc brake rotor shield. 8. Disconnect the steering linkage from the integral front wheel spindle and spindle arm by removing the cotter pin and nut and then removing the front wheel spindle tie rod from the spindle arm with a Tie Rod End Remover or equivalent. 9. Remove the cotter pin and castellated nut from the lower ball joint stud. 10. Remove the nut from the axle clamp bolt and remove the bolt from the axle. 11. Remove the camber adjuster from the upper ball joint stud and axle beam. If required, use Ball Joint Removing Tool or equivalent to remove adjuster. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 7110 CAUTION: Do not use a pickle fork to separate the ball joint from the axle as this will damage the seal and the ball joint socket. 12. Strike the inside area of the axle as shown to pop lower ball joints loose from the axle beam. 13. Remove the front wheel spindle and ball joint from the axle. Installation 1. Place the front wheel spindle and the ball joints into the axle. 2. Install lower ball joint stud nut and tighten to 148-202 N-m (109-149 lb-ft). Continue tightening the castellated nut until it lines up with the hole in the stud. Install the cotter pin. NOTE: If camber adjustment is necessary, special adjusters must be installed. 3. Install the camber adjuster in the upper front wheel spindle over the upper ball joint stud. Align adjuster properly. 4. Install the clamp bolt into the axle boss. Tighten the nut to 87-119 N-m (64-88 lb-ft). 5. Install the front disc brake rotor shield. 6. Pack the bearing cone and roller and front wheel bearing with a lithium-base grease, Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification. 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. 7. Install the bearing cone and roller and wheel hub grease seal. 8. Install the hub and rotor on the front wheel spindle. 9. Install the front wheel bearing, washer and nut. Adjust bearing end play. 10. Install the nut retainer, cotter pin, and dust cap. 11. Install the disc brake caliper. 12. Connect the steering linkage to the front wheel spindle. Tighten the nut to 70-100 N-m (52-74 lb-ft) and advance the nut as required for installation of the cotter pin. 13. Install the wheel and tire assembly. 14. Lower the vehicle. 15. Check and, if necessary, adjust the toe setting. 16. Check the brakes for proper operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Service and Repair Radius Arm: Service and Repair REMOVAL AND INSTALLATION 1. Remove coil spring. 2. Remove spring lower seat from radius arm. 3. Remove radius arm and stabilizer bracket (if equipped) attaching nut and bolt from axle. 4. Remove radius arm from vehicle. 5. Remove spacer, inner insulator and retainer from radius arm stud. 6. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair Spindle: Service and Repair Removal 1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the disc brake caliper from the rotor and wire it out of the way. 4. Remove the dust cap, cotter pin, nut retainer, nut, washer, and front wheel bearing. 5. Remove the rotor from the front wheel spindle. 6. Remove bearing cone and roller and wheel hub grease seal. Discard the seal. 7. Remove front disc brake rotor shield. 8. Disconnect the steering linkage from the integral front wheel spindle and spindle arm by removing the cotter pin and nut and then removing the front wheel spindle tie rod from the spindle arm with a Tie Rod End Remover or equivalent. 9. Remove the cotter pin and castellated nut from the lower ball joint stud. 10. Remove the nut from the axle clamp bolt and remove the bolt from the axle. 11. Remove the camber adjuster from the upper ball joint stud and axle beam. If required, use Ball Joint Removing Tool or equivalent to remove adjuster. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Page 7117 CAUTION: Do not use a pickle fork to separate the ball joint from the axle as this will damage the seal and the ball joint socket. 12. Strike the inside area of the axle as shown to pop lower ball joints loose from the axle beam. 13. Remove the front wheel spindle and ball joint from the axle. Installation 1. Place the front wheel spindle and the ball joints into the axle. 2. Install lower ball joint stud nut and tighten to 148-202 N-m (109-149 lb-ft). Continue tightening the castellated nut until it lines up with the hole in the stud. Install the cotter pin. NOTE: If camber adjustment is necessary, special adjusters must be installed. 3. Install the camber adjuster in the upper front wheel spindle over the upper ball joint stud. Align adjuster properly. 4. Install the clamp bolt into the axle boss. Tighten the nut to 87-119 N-m (64-88 lb-ft). 5. Install the front disc brake rotor shield. 6. Pack the bearing cone and roller and front wheel bearing with a lithium-base grease, Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification. 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. 7. Install the bearing cone and roller and wheel hub grease seal. 8. Install the hub and rotor on the front wheel spindle. 9. Install the front wheel bearing, washer and nut. Adjust bearing end play. 10. Install the nut retainer, cotter pin, and dust cap. 11. Install the disc brake caliper. 12. Connect the steering linkage to the front wheel spindle. Tighten the nut to 70-100 N-m (52-74 lb-ft) and advance the nut as required for installation of the cotter pin. 13. Install the wheel and tire assembly. 14. Lower the vehicle. 15. Check and, if necessary, adjust the toe setting. 16. Check the brakes for proper operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 REMOVAL AND INSTALLATION 1. Raise rear of vehicle and support at frame. Support axle with a suitable jack. 2. Disconnect shock absorbers from lower mountings. 3. Remove two U-bolts and the U-bolt plate. 4. Lower axle assembly and remove upper and lower rear shackle bolts, then pull rear shackle assembly from bracket and spring. 5. Remove spring mounting nut and bolt, then lower spring assembly from vehicle. 6. Lower axle assembly and remove spring front bolt from hanger. Remove two attaching bolts from rear of spring, then lower spring assembly from vehicle. 6. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear > Page 7122 Suspension Spring ( Coil / Leaf ): Service and Repair Coil Spring REMOVAL AND INSTALLATION 1. Raise front of vehicle and support with stands. Support axle with a suitable jack. NOTES: ^ 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair Suspension Strut / Shock Absorber: Service and Repair REMOVAL AND INSTALLATION 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7130 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7131 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7132 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7133 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7134 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7135 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7136 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7137 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7138 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7139 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7140 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7141 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7142 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7143 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7144 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7145 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7146 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7147 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7148 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7149 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7150 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7151 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7152 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7153 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7154 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7155 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7156 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7157 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7158 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7159 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7160 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7161 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7162 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7163 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7164 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7165 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7166 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7167 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7168 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7169 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7170 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7171 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7172 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7173 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7174 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7175 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7176 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7177 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7178 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7179 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7180 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7181 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7182 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7183 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7184 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7185 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7186 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7187 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7188 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7189 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7190 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7191 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7192 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7193 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7194 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7195 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7196 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7197 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7198 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7199 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7200 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7201 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7202 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7203 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7204 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7205 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7206 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7207 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7208 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7209 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7210 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7211 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7212 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7213 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7214 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7215 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7216 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7217 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7218 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7219 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7220 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7221 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7222 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7223 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7224 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 7225 Wheel Bearing: Specifications Wheel Bearing Adjusting Nut [1] ...................................................................................................................................................... 23-34 Nm (17-25 ft lb) Bearing End Play ............................................................................................. .................................................................. 0.006-0.127mm (.00025-.005 in) Hub and Rotor Rotation Torque ................................................................................................................................................. 1.13-2.82 Nm (10-25 in lb) [1] Back nut off approximately one half turn. Tighten nut to 2.03-2.26 Nm (18-20 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Adjustments > Front Wheel Bearing: Adjustments Front 1. Raise the vehicle until the tire clears the floor and install safety stands. 2. Remove the wheel cover or hub cap, if so equipped. 3. Using a suitable tool, remove the grease cap from the hub. Wipe the excess grease from the end of the spindle. Remove the cotter pin and locknut. 4. Loosen the adjusting nut three turns. Attempt to obtain running clearance between the rotor brake surface and the disc pads by rocking the wheel, hub and rotor assembly in and out several times to push the pads away from the rotor. NOTE: Do not pry on the caliper phenolic piston. 5. If running clearance cannot be maintained throughout bearing adjustment in Steps 5 and 6, the caliper must be removed. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 6. Tighten wheel bearing adjusting nut to 23-34 Nm (17-25 ft lb) while rotating the disc brake rotor in the opposite direction. 7. Back nut off approximately one half turn. 8. Tighten nut to 2.03-2.26 Nm (18-20 in lb) while rotating the disc brake rotor. ^ End play should be 0.006-0.127mm (.00025-.005 in). ^ Torque required to rotate the hub should be 1.13-2.82 Nm (10-25 in lb). 9. Install the retainer and new cotter pin bending both ends of cotter pin around retainer. Install grease cap. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Adjustments > Front > Page 7228 Wheel Bearing: Adjustments Rear REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove axle shaft bolts. 5. Using suitable dolly, raise wheel until all weight is removed from wheel bearings. 6. Remove brake drum. 7. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 8. Remove outer bearing, then pull wheel assembly from axle. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. Check for proper seating of bearing cup by trying to insert a 0.0015 in feeler gauge between cups and wheel hub. The gauge should not enter beneath cup. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 15. Install outer wheel bearing and start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 65-75 ft lb Rotate hub occasionally while tightening to set bearings. After torquing to specifications, ratchet back 90°, then torque to 15-20 ft lb. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL AND INSTALLATION 1. Raise and support front of vehicle and remove front wheels. 2. Remove brake caliper and position aside, leaving brake lines attached. CAUTION: 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. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7231 Wheel Bearing: Service and Repair Rear REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove wheel assembly, then remove brake drum. 5. Remove axle shaft bolts. 6. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 7. Install Step Plate Adapter tool No. D80L-630-7 and Puller tool No. D80L-1002-L, or equivalents. Loosen hub until it can be removed. 8. Remove hub, then outer bearing. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Install outer wheel bearing into hub, then slide hub assembly onto axle housing spindle. 15. Start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 55-65 ft lb. Rotate hub occasionally while tightening, to set bearings. After torquing to specifications, ratchet back five clicks (1/8 turn) for new bearing or eight clicks (1/6 turn) for used bearings. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb and tighten axle shaft retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle Wheel Hub: Service and Repair Dana/Spicer Integral Housing Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove axle shaft bolts. 5. Using suitable dolly, raise wheel until all weight is removed from wheel bearings. 6. Remove brake drum. 7. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 8. Remove outer bearing, then pull wheel assembly from axle. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. Check for proper seating of bearing cup by trying to insert a 0.0015 in feeler gauge between cups and wheel hub. The gauge should not enter beneath cup. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 15. Install outer wheel bearing and start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 65-75 ft lb Rotate hub occasionally while tightening to set bearings. After torquing to specifications, ratchet back 90°, then torque to 15-20 ft lb. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle > Page 7236 Wheel Hub: Service and Repair Ford Integral Carrier Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove wheel assembly, then remove brake drum. 5. Remove axle shaft bolts. 6. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 7. Install Step Plate Adapter tool No. D80L-630-7 and Puller tool No. D80L-1002-L, or equivalents. Loosen hub until it can be removed. 8. Remove hub, then outer bearing. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Install outer wheel bearing into hub, then slide hub assembly onto axle housing spindle. 15. Start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 55-65 ft lb Rotate hub occasionally while tightening, to set bearings. After torquing to specifications, ratchet back five clicks (1/8 turn) for new bearing or eight clicks (1/6 turn) for used bearings. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb and tighten axle shaft retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle Wheel Seal: Service and Repair Dana/Spicer Integral Housing Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove axle shaft bolts. 5. Using suitable dolly, raise wheel until all weight is removed from wheel bearings. 6. Remove brake drum. 7. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 8. Remove outer bearing, then pull wheel assembly from axle. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. Check for proper seating of bearing cup by trying to insert a 0.0015 in feeler gauge between cups and wheel hub. The gauge should not enter beneath cup. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 15. Install outer wheel bearing and start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 65-75 ft lb. Rotate hub occasionally while tightening to set bearings. After torquing to specifications, ratchet back 90°, then torque to 15-20 ft lb. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle > Page 7241 Wheel Seal: Service and Repair Ford Integral Carrier Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove wheel assembly, then remove brake drum. 5. Remove axle shaft bolts. 6. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 7. Install Step Plate Adapter tool No. D80L-630-7 and Puller tool No. D80L-1002-L, or equivalents. Loosen hub until it can be removed. 8. Remove hub, then outer bearing. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Install outer wheel bearing into hub, then slide hub assembly onto axle housing spindle. 15. Start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 55-65 ft lb. Rotate hub occasionally while tightening, to set bearings. After torquing to specifications, ratchet back five clicks (1/8 turn) for new bearing or eight clicks (1/6 turn) for used bearings. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb and tighten axle shaft retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7247 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7248 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7249 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7250 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7251 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7252 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7253 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7254 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7255 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7256 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7257 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7258 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7259 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7260 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7261 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7262 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7263 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7264 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7265 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7266 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7267 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7268 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7269 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7270 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7271 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7272 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7273 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7274 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7275 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7276 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7277 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7278 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7279 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7280 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7281 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7282 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7283 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7284 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7285 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7286 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7287 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7288 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7289 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7290 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7291 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7292 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7293 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7294 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7295 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7296 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7297 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7299 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7301 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7302 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7303 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7304 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7305 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7306 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7307 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7308 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7309 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7310 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7311 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7312 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7313 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7314 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7315 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7316 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7317 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7318 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7319 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7320 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7321 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7322 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7323 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7324 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7325 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7326 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7327 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7328 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7329 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7330 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7331 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7332 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7333 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7334 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7335 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7336 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7337 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7338 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7339 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7340 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7341 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7346 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7347 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7348 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7349 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7350 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7351 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7352 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7353 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7354 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7355 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7356 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7357 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7358 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7359 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7360 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7361 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7362 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7363 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7364 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7365 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7366 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7367 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7368 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7369 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7370 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > 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> Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7375 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7376 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7377 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7378 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7379 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7380 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7381 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7382 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo 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Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7387 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7388 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7389 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7390 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7391 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7392 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7393 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7394 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7395 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7396 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7397 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7398 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7399 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7401 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7402 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7403 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7404 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7405 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component 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Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7414 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7415 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7416 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7417 Ford E 350 Van Workshop Manual (V8-7.3L 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Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7422 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7423 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7424 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7425 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7426 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7427 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7428 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7429 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7430 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7431 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7432 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7433 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7434 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7435 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7436 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7437 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7438 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7439 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7440 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7441 Wheels: Specifications 5 LUG WHEEL 1/2-20 .................................................................................................................................................. ........................................... 135 Nm (100 lb ft) 8 LUG WHEEL 9/16-18 ................................................................................................................................................ ........................................... 190 Nm (140 lb ft) NOTE: Torque specifications are for clean, dirt and paint free dry bolt and nut threads. Never use oil or grease on studs and nuts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7446 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7447 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7448 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7449 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7450 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7451 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7452 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7453 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7454 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7455 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7456 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7457 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7458 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7459 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7460 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7461 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7462 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7463 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7464 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7465 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7466 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7467 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7468 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7469 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7470 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7471 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7472 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7473 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7474 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7475 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7476 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7477 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7478 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7479 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7480 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7481 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7482 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7483 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7484 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7485 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7486 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7487 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7488 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7489 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7490 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7491 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7492 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7493 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7494 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7495 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7496 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7497 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7498 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7499 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7500 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7501 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7502 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7503 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7504 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7505 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7506 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7507 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7508 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7509 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7510 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7511 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7512 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7513 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7514 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7515 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7516 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7517 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7518 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7519 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7520 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7521 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7522 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7523 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7524 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7525 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7526 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7527 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7528 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7529 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7530 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7531 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7532 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7533 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7534 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7535 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7536 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7537 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7538 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7539 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 7540 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 7541 Wheel Bearing: Specifications Wheel Bearing Adjusting Nut [1] ...................................................................................................................................................... 23-34 Nm (17-25 ft lb) Bearing End Play ............................................................................................. .................................................................. 0.006-0.127mm (.00025-.005 in) Hub and Rotor Rotation Torque ................................................................................................................................................. 1.13-2.82 Nm (10-25 in lb) [1] Back nut off approximately one half turn. Tighten nut to 2.03-2.26 Nm (18-20 in lb). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Adjustments > Front Wheel Bearing: Adjustments Front 1. Raise the vehicle until the tire clears the floor and install safety stands. 2. Remove the wheel cover or hub cap, if so equipped. 3. Using a suitable tool, remove the grease cap from the hub. Wipe the excess grease from the end of the spindle. Remove the cotter pin and locknut. 4. Loosen the adjusting nut three turns. Attempt to obtain running clearance between the rotor brake surface and the disc pads by rocking the wheel, hub and rotor assembly in and out several times to push the pads away from the rotor. NOTE: Do not pry on the caliper phenolic piston. 5. If running clearance cannot be maintained throughout bearing adjustment in Steps 5 and 6, the caliper must be removed. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 6. Tighten wheel bearing adjusting nut to 23-34 Nm (17-25 ft lb) while rotating the disc brake rotor in the opposite direction. 7. Back nut off approximately one half turn. 8. Tighten nut to 2.03-2.26 Nm (18-20 in lb) while rotating the disc brake rotor. ^ End play should be 0.006-0.127mm (.00025-.005 in). ^ Torque required to rotate the hub should be 1.13-2.82 Nm (10-25 in lb). 9. Install the retainer and new cotter pin bending both ends of cotter pin around retainer. Install grease cap. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Adjustments > Front > Page 7544 Wheel Bearing: Adjustments Rear REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove axle shaft bolts. 5. Using suitable dolly, raise wheel until all weight is removed from wheel bearings. 6. Remove brake drum. 7. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 8. Remove outer bearing, then pull wheel assembly from axle. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. Check for proper seating of bearing cup by trying to insert a 0.0015 in feeler gauge between cups and wheel hub. The gauge should not enter beneath cup. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 15. Install outer wheel bearing and start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 65-75 ft lb Rotate hub occasionally while tightening to set bearings. After torquing to specifications, ratchet back 90°, then torque to 15-20 ft lb. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL AND INSTALLATION 1. Raise and support front of vehicle and remove front wheels. 2. Remove brake caliper and position aside, leaving brake lines attached. CAUTION: 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. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7547 Wheel Bearing: Service and Repair Rear REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove wheel assembly, then remove brake drum. 5. Remove axle shaft bolts. 6. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 7. Install Step Plate Adapter tool No. D80L-630-7 and Puller tool No. D80L-1002-L, or equivalents. Loosen hub until it can be removed. 8. Remove hub, then outer bearing. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Install outer wheel bearing into hub, then slide hub assembly onto axle housing spindle. 15. Start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 55-65 ft lb. Rotate hub occasionally while tightening, to set bearings. After torquing to specifications, ratchet back five clicks (1/8 turn) for new bearing or eight clicks (1/6 turn) for used bearings. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb and tighten axle shaft retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 96114 > May > 96 > Center Wheel Ornament - Falls Off Wheel Cover: Customer Interest Center Wheel Ornament - Falls Off Article No. 96-11-4 05/20/96 ^ TRIM - EXTERIOR - CENTER WHEEL ORNAMENT FALLING OFF - VEHICLES BUILT THROUGH 12/8/95 WITH 16 INCH WHEELS ^ WHEELS - CENTER WHEEL ORNAMENT FALLING OFF - VEHICLES BUILT THROUGH 12/8/95 WITH 16 INCH WHEELS LIGHT TRUCK: 1995-96 E-25O, E-35O, F-25O, F-350 ISSUE: The center wheel ornament may fall off of the wheel(s) while driving. This may be caused by broken retention clips, poor clip retention and/or improper installation. ACTION: Remove any existing center wheel ornaments and replace all four (4) of the center wheel ornaments using the wheel ornament kit. The new ornaments have improved clip retention and an easier installation procedure to reduce the possibility of improper installation. Make sure the ornament is centered and pressed on evenly around the outside edge with both hands. Do not hit the ornament to install it as this may damage the ornament. PART NUMBER PART NAME F5UZ-1A108-VB Wheel Ornament Kit (E-250 SRW With Semi-Float Axle) F5TZ-1A108-XB Wheel Ornament Kit (E/F-250-35O 4X2 With Full-Float Axle) F5TZ-1A108-UB Wheel Ornament Kit (F-250/350 4X4 SRW) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961104A Replace Wheel Ornaments 0.4 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1130 02 OASIS CODES: 108000, 306000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 96114 > May > 96 > Center Wheel Ornament - Falls Off Wheel Cover: All Technical Service Bulletins Center Wheel Ornament - Falls Off Article No. 96-11-4 05/20/96 ^ TRIM - EXTERIOR - CENTER WHEEL ORNAMENT FALLING OFF - VEHICLES BUILT THROUGH 12/8/95 WITH 16 INCH WHEELS ^ WHEELS - CENTER WHEEL ORNAMENT FALLING OFF - VEHICLES BUILT THROUGH 12/8/95 WITH 16 INCH WHEELS LIGHT TRUCK: 1995-96 E-25O, E-35O, F-25O, F-350 ISSUE: The center wheel ornament may fall off of the wheel(s) while driving. This may be caused by broken retention clips, poor clip retention and/or improper installation. ACTION: Remove any existing center wheel ornaments and replace all four (4) of the center wheel ornaments using the wheel ornament kit. The new ornaments have improved clip retention and an easier installation procedure to reduce the possibility of improper installation. Make sure the ornament is centered and pressed on evenly around the outside edge with both hands. Do not hit the ornament to install it as this may damage the ornament. PART NUMBER PART NAME F5UZ-1A108-VB Wheel Ornament Kit (E-250 SRW With Semi-Float Axle) F5TZ-1A108-XB Wheel Ornament Kit (E/F-250-35O 4X2 With Full-Float Axle) F5TZ-1A108-UB Wheel Ornament Kit (F-250/350 4X4 SRW) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961104A Replace Wheel Ornaments 0.4 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1130 02 OASIS CODES: 108000, 306000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle Wheel Hub: Service and Repair Dana/Spicer Integral Housing Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove axle shaft bolts. 5. Using suitable dolly, raise wheel until all weight is removed from wheel bearings. 6. Remove brake drum. 7. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 8. Remove outer bearing, then pull wheel assembly from axle. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. Check for proper seating of bearing cup by trying to insert a 0.0015 in feeler gauge between cups and wheel hub. The gauge should not enter beneath cup. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 15. Install outer wheel bearing and start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 65-75 ft lb Rotate hub occasionally while tightening to set bearings. After torquing to specifications, ratchet back 90°, then torque to 15-20 ft lb. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle > Page 7565 Wheel Hub: Service and Repair Ford Integral Carrier Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove wheel assembly, then remove brake drum. 5. Remove axle shaft bolts. 6. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 7. Install Step Plate Adapter tool No. D80L-630-7 and Puller tool No. D80L-1002-L, or equivalents. Loosen hub until it can be removed. 8. Remove hub, then outer bearing. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Install outer wheel bearing into hub, then slide hub assembly onto axle housing spindle. 15. Start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 55-65 ft lb Rotate hub occasionally while tightening, to set bearings. After torquing to specifications, ratchet back five clicks (1/8 turn) for new bearing or eight clicks (1/6 turn) for used bearings. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb and tighten axle shaft retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 7570 ^ 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 7571 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 7572 Wheel Fastener: Specifications Wheel Lug Torque 9/16-18 ................................................................................................................................................ ........................................... 190 Nm (140 lb ft) NOTE: Torque specifications are for clean, dirt and paint free dry bolt and nut threads. Never use oil or grease on studs and nuts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle Wheel Seal: Service and Repair Dana/Spicer Integral Housing Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove axle shaft bolts. 5. Using suitable dolly, raise wheel until all weight is removed from wheel bearings. 6. Remove brake drum. 7. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 8. Remove outer bearing, then pull wheel assembly from axle. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. Check for proper seating of bearing cup by trying to insert a 0.0015 in feeler gauge between cups and wheel hub. The gauge should not enter beneath cup. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 15. Install outer wheel bearing and start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 65-75 ft lb. Rotate hub occasionally while tightening to set bearings. After torquing to specifications, ratchet back 90°, then torque to 15-20 ft lb. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle > Page 7577 Wheel Seal: Service and Repair Ford Integral Carrier Type Axle REMOVAL AND INSTALLATION 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Release parking brake, then back off rear brake adjustment, if necessary. 4. Remove wheel assembly, then remove brake drum. 5. Remove axle shaft bolts. 6. Remove axle shaft and discard gasket, then the wheel bearing hub nut using Hub Wrench tool No. T85T-4252-AH, or equivalent. 7. Install Step Plate Adapter tool No. D80L-630-7 and Puller tool No. D80L-1002-L, or equivalents. Loosen hub until it can be removed. 8. Remove hub, then outer bearing. 9. Using screwdriver, remove inner seal. Remove inner bearing. 10. Using brass drift, remove bearing cups. 11. Inspect bearings and cups, replace if worn or damaged. 12. Install new cups with Bearing Cup Replacer tool No. T75T-1225-A or B, or equivalent. 13. Lubricate bearing assemblies and place inner assembly into wheel hub. Install new hub inner seal. 14. Install outer wheel bearing into hub, then slide hub assembly onto axle housing spindle. 15. Start adjuster nut. 16. Using Hub Wrench tool No. T85T-4252-AH, or equivalent, torque hub nut to 55-65 ft lb. Rotate hub occasionally while tightening, to set bearings. After torquing to specifications, ratchet back five clicks (1/8 turn) for new bearing or eight clicks (1/6 turn) for used bearings. 17. Install axle shaft and new flange gasket, then install retaining bolts and tighten bolts until they seat. 18. Install brake drum, wheel assembly, then lower vehicle. 19. Adjust brakes. 20. Tighten wheel lug nuts to 140 ft lb and tighten axle shaft retaining bolts. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams Blend Door Actuator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 7583 Air Door Actuator / Motor: Service and Repair Vacuum Control Motor and Door Installation REMOVAL 1. Remove the auxiliary heater and air conditioning assembly. 2. Remove the screw that attaches the mode door base to the auxiliary unit housing. 3. Unsnap the mounting base from the auxiliary unit housing. Remove the vacuum control motor (18A318) and mode door as an assembly. 4. Disconnect the mode door from the vacuum control motor. INSTALL 5. For installation, follow removal steps in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair Air Duct: Service and Repair REMOVAL AND INSTALLATION 1. If a spanner wrench of suitable size is available, use it to rotate the register and louver assembly until the louver retainer ears align with the front to rear centerline of the vehicle. Air Duct Removal Tool NOTE: If a spanner wrench is not available, a piece of 1/8-inch diameter rod stock may be made locally into a tool with the dimensions called out in the above illustration. Air Register 2. For accessibility, open the register louvers to expose the holes in the retainer ears. Insert the open ends of the fabricated tool into the holes in the retainer ears; then, rotate the register and louver assembly into its removable position. CAUTION: Do not use a screwdriver to pry the assembly out of the opening in the headliner. It could result in damage to the headliner or register assembly. 3. While pushing the assembly rearward, pull downward on the front of the register. A slight twisting motion may be needed to properly align the retainer ears with the clearance openings in the headliner. 4. For installation, follow removal steps in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation Blower Motor: Description and Operation Rear Air Control Switch OPERATION The auxiliary air conditioning system contains a blower motor (18527). It is controlled by a heater blower motor switch (18578) on the vehicle's instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor Blower Motor: Service and Repair Front Blower Motor REMOVAL AND INSTALLATION 1. Disconnect battery ground cable. 2. Disconnect electrical connector from blower motor. Remove the housing to motor cooling tube. 3. Remove blower motor attaching screws, then the blower motor and wheel assembly. 4. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor > Page 7592 Blower Motor: Service and Repair Rear Blower Motor View REMOVAL AND INSTALLATION 1. Remove the third, fourth and fifth bench seats (if equipped). 2. Remove the left center bolster trim panel, left lower front trim panel, left rear lower and upper trim panels (if equipped). 3. Disconnect the blower motor housing tube (19A786) tube from the auxiliary unit housing. 4. Disconnect the electrical connector. 5. Remove the mounting screws and remove the blower motor (18527). 6. For installation, follow removal steps in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay Blower Motor Relay: Locations Auxiliary Blower Relay Full Body View (Part 1 Of 3) The Auxiliary Blower Motor Relay is located at the left rear corner of the vehicle, above wheel well. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 7597 Blower Motor Relay: Locations Auxiliary High Blower Motor Relay Full Body View (Part 3 Of 3) The Auxiliary High Blower Motor Relay is located at the left rear corner of the vehicle, above wheel well. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 7598 Blower Motor Relay: Locations Front Blower Relay Engine Compartment View The Blower Motor Relay is located at the LH front of engine compartment, near starter relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay Auxiliary Blower Motor Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay > Page 7601 Auxiliary High Blower Motor Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair Blower Motor Resistor: Service and Repair Rear Air Blower Switch Resistor REMOVAL AND INSTALLATION 1. Remove the third, fourth and fifth bench seats (if equipped). 2. Remove the left center bolster trim panel, left lower front trim panel. left rear lower and upper trim panels (if equipped). 3. Disconnect the electrical connector. 4. Remove the mounting screws and remove the heater blower motor switch resistor (18591) 5. For installation, follow removal procedures in reverse order. Check blower motor operation prior to installing trim. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams Auxiliary A/C-Heater Blower Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary Blower Motor Switch: Testing and Inspection Auxiliary Auxiliary A/C-Heater Blower Switch - Component Testing Procedure Auxiliary A/C-Heater Blower Switch - Terminal Locations Auxiliary A/C-Heater Blower Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary > Page 7610 Blower Motor Switch: Testing and Inspection Front Blower Switch Front Blower Switch - Component Testing Procedure Front Blower Switch - Terminal Locations Front Blower Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary > Page 7611 Blower Motor Switch: Testing and Inspection Rear Auxiliary Rear Auxiliary Blower Switch - Component Testing Procedure Rear Auxiliary Blower Switch - Terminal Locations Rear Auxiliary Blower Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and Inspection > Page 7612 Blower Motor Switch: Service and Repair Rear Air Control Switch View REMOVAL AND INSTALLATION 1. Using a screwdriver, carefully pry the rear control assembly out of the headliner. 2. Disconnect the electrical connector from the heater blower motor switch (18578). 3. If necessary, remove the knob from the heater blower motor switch and remove the switch from the rear control unit. 4. For installation, follow removal steps in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This model is not equipped with a cabin air filter Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch <--> [Compressor Clutch] > Component Information > Technical Service Bulletins > Customer Interest for A/C Compressor Clutch: > 94239 > Nov > 94 > A/C - Little or No Cooling A/C Compressor Clutch: Customer Interest A/C - Little or No Cooling Article No. 94-23-9 11/14/94 AIR CONDITIONING - LITTLE OR NO COOLING - FS-10 COMPRESSORS - EXCESSIVE CLUTCH AIR GAP - ALL ENGINES EXCEPT 1.8L ESCORT/TRACER AND 3.0L, 3.2L SHO VEHICLES BUILT THROUGH 9/19/94 FORD: 1995 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1995 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER, WINDSTAR ISSUE: About 6500 1995 vehicles with factory installed A/C may have a short thread in the FS-10 A/C compressor shaft that holds the clutch bolt. The bolt could bottom out and leave a gap between the the bolt head and the clutch disc. This could lead to the clutch disc moving away from the pulley resulting in an excessive air gap which could prevent the A/C clutch from engaging. ACTION: If this condition exists, adjust the air gap according to the service procedures found in Section 12-00 of the appropriate Service Manual and install clutch spacer(s) under the head of the clutch bolt as a washer. The largest spacer is approximately 1 mm thick and can be found in spacer pack (F1VY-19D648-A). PART NUMBER PART NAME CLASS F1VY-19D648-A Spacer Pack A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 942309A Adjust Air Gap 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 19D648 79 OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch <--> [Compressor Clutch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for A/C Compressor Clutch: > 94239 > Nov > 94 > A/C - Little or No Cooling A/C Compressor Clutch: All Technical Service Bulletins A/C - Little or No Cooling Article No. 94-23-9 11/14/94 AIR CONDITIONING - LITTLE OR NO COOLING - FS-10 COMPRESSORS - EXCESSIVE CLUTCH AIR GAP - ALL ENGINES EXCEPT 1.8L ESCORT/TRACER AND 3.0L, 3.2L SHO VEHICLES BUILT THROUGH 9/19/94 FORD: 1995 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1995 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER, WINDSTAR ISSUE: About 6500 1995 vehicles with factory installed A/C may have a short thread in the FS-10 A/C compressor shaft that holds the clutch bolt. The bolt could bottom out and leave a gap between the the bolt head and the clutch disc. This could lead to the clutch disc moving away from the pulley resulting in an excessive air gap which could prevent the A/C clutch from engaging. ACTION: If this condition exists, adjust the air gap according to the service procedures found in Section 12-00 of the appropriate Service Manual and install clutch spacer(s) under the head of the clutch bolt as a washer. The largest spacer is approximately 1 mm thick and can be found in spacer pack (F1VY-19D648-A). PART NUMBER PART NAME CLASS F1VY-19D648-A Spacer Pack A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 942309A Adjust Air Gap 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 19D648 79 OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch <--> [Compressor Clutch] > Component Information > Technical Service Bulletins > Page 7630 A/C Compressor Clutch: Specifications Compressor Clutch Air Gap ................................................................................................................. ........................................................... 0.018-0.033 in Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures Condenser HVAC: Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures > Page 7635 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Function Selector Switch <--> [Control Assembly, HVAC] > Component Information > Diagrams Temperature Control Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Function Selector Switch <--> [Control Assembly, HVAC] > Component Information > Diagrams > Page 7639 Function Selector Switch: Description and Operation Front Climate Control Switches CONTROL SWITCH, REAR Systems that have both front and rear control capabilities use both front and rear control assemblies. These systems provide the following settings for the blower motor (18527): OFF, REAR CONTROL, LOW, MED and HIGH. By setting the front heater blower motor switch (18578) to the REAR CONTROL position, the blower motor can be controlled by the heater blower motor switch in the rear control assembly. FRONT CLIMATE CONTROL ASSEMBLY The driver and front seat passenger have access to the front A/C control (19980) located in the instrument panel (04320). This is the main control and provides settings for temperature, function selector and main and auxiliary blower speed selection. There are five combinations of front control assemblies available for Econoline vehicles with three having auxiliary heating and/or air conditioning controls: 1. Front Standard Heater Only. 2. Front A/C-Heater Only. 3. Front Heater w/Aux Heat. 4. Front A/C w/Aux A/C & Heat W/O Rear Control. 5. Front A/C w/Aux A/C & Heat W/Rear Fan Control. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Function Selector Switch <--> [Control Assembly, HVAC] > Component Information > Diagrams > Page 7640 Function Selector Switch: Testing and Inspection Function Selector Switch - Component Testing Procedure Function Selector Switch - Terminal Locations Function Selector Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications A/C Coupler O-ring: Technical Service Bulletins A/C - New O Ring Applications Article No. 96-20-8 09/23/96 ^ AIR CONDITIONING - NEW 0-RING APPLICATIONS - THICKER 0-RINGS FOR SPRING LOCK FITTINGS - SERVICE TIP ^ AIR CONDITIONING - SPRING LOCK COUPLING CLEANING PROCEDURE - SERVICE TIP FORD: 1992-93 FESTIVA 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992 MARK VII 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-96 BRONCO 1992-97 AEROSTAR, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, F-47, RANGER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 MOUNTAINEER ISSUE: A new air conditioning spring lock coupling cleaning procedure has been developed. This procedure is required for a thicker O-ring that has been released for servicing spring lock couplings. These O-rings have a larger cross-sectional diameter for improved sealing. The thicker O-ring is green in color and identifiable only by the part number. These are service only O-rings and will not be used in production. ACTION: Clean the Spring Lock Coupling(s) (SLC), if their service is required, and install the new thicker O-rings by referring to the following Service Procedure for details. SERVICE PROCEDURE 1. Recover refrigerant from the A/C system. 2. Disconnect SLC(s). 3. Remove old O-rings using a plastic O-ring tool and discard. Plastic O-ring Service Tools are available from Rotunda in the R-134a/R-12 Port kit (164R2602) or the 0-Ring Pick/Valve Core Removal Tool kit (164R2604). These items can be ordered by calling 1-800-768-8632 (Mon-Fri, 8AM-5PM EST). When prompted, press choice 2 for dealership supply orders. 4. Check the female SLC O-ring sealing surface for scratches, corrosion, or debris from deteriorated O-rings. Clean any surface residue from the inside of the couplings by using the following procedure (Steps 4a-4j): a. Obtain the following shop equipment and cleaning supplies locally: ^ 3-1/2" length of steel brazing rod ^ YN-9 (mineral) oil for R-12 systems or YN-12-B (PAG) oil for R-134a systems ^ Variable speed electric drill ^ Safety goggles or glasses Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 7646 ^ Lint free cloth ^ 12" length of natural fiber string (twine or kite string) ^ Abrasive material - maroon colored 3M "Scotch Brite" pad cut in strips as follows: SLC Abrasive Strip Size Dimension 3/8" 1" X 2" 1/2" 1" X 2" 5/8" 1" X 3" 3/4" 1" x 4" b. Fabricate a cleaning tool (Figure 1). c. Determine coupling size and select the appropriate length of abrasive strip from the Step 4a table. d. Insert abrasive strip into the cleaning tool (Figure 2). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 7647 e. Insert completed assembly into drill and tighten chuck securely. f. Coat the abrasive strip in appropriate refrigerant oil. g. Roll abrasive strip around cleaning tool (Figure 3). NOTE: DO NOT ALLOW THE DRILL SPEED TO EXCEED 1500 RPM AS TOOL SEPARATION MAY OCCUR. h. Using a variable speed drill set at a low speed, slowly insert cleaning assembly into the female coupling. Clean using a moderate speed for approximately 1 minute or until surface is clean. Maintain low speed drill rotation while removing the cleaning assembly to prevent axial scratches, which may cause future leaks. NOTE: IT IS IMPORTANT TO USE A LINT FREE CLOTH TO PREVENT MATERIAL FIBERS FROM REMAINING ON THE 0-RING SEALING SURFACE AND CAUSING FUTURE LEAKS. i. Remove all cleaning residue from the coupling using a lint free cloth. j. Inspect O-ring sealing surface for grooves. If grooves or scratches cannot be removed, replace the component. 5. Inspect the male SLC O-ring grooves for scratches, corrosion, or debris from O-ring deterioration. Remove any surface residue from the O-ring grooves by cleaning using the following procedure (Steps 5a-5b): Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 7648 a. Loop the 12" length of natural fiber string around SLC and clean O-ring sealing surface (Figure 4). b. Remove all cleaning residue using a lint free cloth. NOTE: ONLY USE NEW GREEN 0-RINGS. THE USE OF ANY 0-RING SEALS OTHER THAN SPECIFIED MAY ALLOW CONNECTION TO LEAK INTERMITTENTLY DURING VEHICLE OPERATION. 6. Reassemble the SLC by referring to the following procedure (Steps 6a-6e): a. Lubricate the new O-ring seal using appropriate refrigerant oil. b. Install new O-rings. c. Lubricate the inside of the female coupling with the appropriate refrigerant oil. d. Install plastic indicator ring into cage opening if indicator ring is to be used. NOTE: IF THE PLASTIC INDICATOR RING IS USED, IT WILL SNAP OUT OF THE CAGE OPENING WHEN THE COUPLING IS CONNECTED TO INDICATE ENGAGEMENT. IF THE INDICATOR RING IS NOT USED, CHECK THE COUPLING ENGAGEMENT BY VERIFYING THAT THE GARTER SPRING IS OVER THE FLARED END OF THE FEMALE COUPLING. e. Fit female coupling to male coupling and push with a twisting motion until the garter spring snaps over the flared end of the female fitting. 7. Repeat procedure as necessary for any remaining couplings. Verify seal integrity by leak testing the coupling. If coupling continues to leak, replace the component. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 7649 OASIS CODES: 208000, 208200, 2O8999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 7650 A/C Coupler O-ring: Technical Service Bulletins A/C O Ring - Availability and Applications Article No. 96-20-7 09/23/96 AIR CONDITIONING - NEW 0-RING AVAILABILITY AND APPLICATIONS - SERVICE TIP FORD: 1992-93 FESTIVA 1992-94 TEMPO 1992 and after ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994 and after ASPIRE 1995 and after CONTOUR LINCOLN-MERCURY: 1992-94 TOPAZ 1992 and after CONTINENTAL, COUGAR, SABLE, TRACER 1993-94 CAPRI 1993 and after MARK VIII 1995 and after MYSTIQUE LIGHT TRUCK: 1992 and after AEROSTAR, BRONCO, ECONOLINE, EXPLORER F-150-350 SERIES, F-47, RANGER 1993 and after VILLAGER 1995 and after WINDSTAR 1997 and after MOUNTAINEER MEDIUM/HEAVY TRUCK: 1992 and after F & B SERIES ISSUE: This bulletin provides climate control system O-ring part number information. ACTION: When servicing A/C systems, refer to the application charts for correct O-ring part numbers. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 7651 The contents of O-ring Service kit F3VY-19D690-A* are as follows: ^ Two (2) 391304-S100** ^ Two (2) 391305-S100 ^ Two (2) 391396-S100** ^ Four (4) 391397-S100** * This O-ring kit will be obsolete and new O-rings will need to be ordered separately. ** These Part Numbers have been replaced by new thicker O-rings. They can be used until stock is depleted. The following are replacement numbers: ^ 391302-S100 replaced by W701993-S ^ 391303-S100 replaced by W701992-S ^ 391304-S100 replaced by W701994-S ^ 391396-S100 replaced by W701993-S ^ 391397-S100 replaced by W701992-S Parts Block OTHER APPLICABLE ARTICLES: 95-2-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 7652 A/C Coupler O-ring: Technical Service Bulletins Air Conditioning - O Ring Removal Service Tip Article No. 95-2-2 01/30/95 AIR CONDITIONING - O-RING REMOVAL FROM SPRING LOCK COUPLER - SERVICE TIP FORD: 1981-95 MUSTANG 1982-83 FAIRMONT 1982-88 EXP 1982-95 CROWN VICTORIA, ESCORT, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-95 TAURUS 1989-95 PROBE 1995 CONTOUR LINCOLN-MERCURY: 1982-83 LN7, ZEPHYR 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1991-95 TRACER 1993-94 CAPRI 1993-95 MARK VIII 1995 MYSTIQUE LIGHT TRUCK: 1982-95 BRONCO, F SUPER DUTY, F-150-350 SERIES, RANGER 1983-90 BRONCO II 1986-95 AEROSTAR 1988-95 ECONOLINE 1991-95 EXPLORER 1995 WINDSTAR This TSB is being republished in its entirety to include the latest level tools and procedures available. ISSUE: Some technicians may use small screwdrivers to remove 0-rings from spring lock coupling fittings. This practice can and has resulted in scratches across the 0-ring grooves in the fittings. Loss of refrigerant charge in the system may result. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 7653 ACTION: It is recommended that a plastic toothpick, or equivalent tool, be used to remove 0-rings. Refer to Figure 1. Do not use the metal O-Ring Tool (T71P-19703-C). Only plastic O-Ring Tool (F5VH-17B017-AA) is approved for O-ring removal. OTHER APPLICABLE ARTICLES: 91-22-5, 93-6-5 SUPERSEDES: 93-15-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 961515 > Jul > 96 > A/C - Water Leaks On Passenger Side Floor Evaporator Case: Customer Interest A/C - Water Leaks On Passenger Side Floor Article No. 96-15-15 07/15/96 AIR CONDITIONING - WATER LEAKING ON PASSENGER SIDE FLOOR LIGHT TRUCK: 1994-96 ECONOLINE This TSB is being republished in its entirety to include the drilling of holes as an additional Step. ISSUE: Condensate may be dripping onto the floor on the passenger side of the vehicle. This may be caused by blockage in the evaporator case drain. ACTION: Modify the evaporator case to allow condensate to drain from the evaporator case through the drain hole provided. Refer to the following Service Procedure for details. SERVICE PROCEDURE For vehicles built before February, 1996, follow the complete Service Procedure. For vehicles built after February, 1996, follow Service Procedure omitting modifying the tab outlined in Step 3. 1. Discharge the A/C system and recover the refrigerant as outlined in Section 12 of the appropriate Econoline Service Manual. 2. Remove the evaporator core as outlined in Section 12 of the appropriate Econoline Service Manual. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 961515 > Jul > 96 > A/C - Water Leaks On Passenger Side Floor > Page 7662 3. Modify the tab on the evaporator case as shown in Figure 1 and drill one (1) 8mm (5/16") hole as shown in Figure 1. 4. Remove any debris from the evaporator case and make sure the evaporator case drain hole is not plugged. 5. Reinstall the evaporator core as outlined in Section 12 of the appropriate Econoline Service Manual. 6. Recharge the A/C system as outlined in Section 12 of the appropriate Econoline Service Manual. NOTE: IN EXTREME CASES WHEN THE ABOVE PROCEDURE DOES NOT COMPLETELY FIX THE CONCERN, ATTACH A FINE SCREEN 13 mm (1/2") DOWNSTREAM OF THE EVAPORATOR CORE TO CATCH FLYING DROPLETS OF CONDENSATE. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-12-14 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961515A Modify Evaporator Case 1.1 Hr. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 961515 > Jul > 96 > A/C - Water Leaks On Passenger Side Floor > Page 7663 DEALER CODING CONDITION BASIC PART NO. CODE 19850 55 OASIS CODES: 110000, 208000, 208300, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 961515 > Jul > 96 > A/C - Water Leaks On Passenger Side Floor Evaporator Case: All Technical Service Bulletins A/C - Water Leaks On Passenger Side Floor Article No. 96-15-15 07/15/96 AIR CONDITIONING - WATER LEAKING ON PASSENGER SIDE FLOOR LIGHT TRUCK: 1994-96 ECONOLINE This TSB is being republished in its entirety to include the drilling of holes as an additional Step. ISSUE: Condensate may be dripping onto the floor on the passenger side of the vehicle. This may be caused by blockage in the evaporator case drain. ACTION: Modify the evaporator case to allow condensate to drain from the evaporator case through the drain hole provided. Refer to the following Service Procedure for details. SERVICE PROCEDURE For vehicles built before February, 1996, follow the complete Service Procedure. For vehicles built after February, 1996, follow Service Procedure omitting modifying the tab outlined in Step 3. 1. Discharge the A/C system and recover the refrigerant as outlined in Section 12 of the appropriate Econoline Service Manual. 2. Remove the evaporator core as outlined in Section 12 of the appropriate Econoline Service Manual. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 961515 > Jul > 96 > A/C - Water Leaks On Passenger Side Floor > Page 7669 3. Modify the tab on the evaporator case as shown in Figure 1 and drill one (1) 8mm (5/16") hole as shown in Figure 1. 4. Remove any debris from the evaporator case and make sure the evaporator case drain hole is not plugged. 5. Reinstall the evaporator core as outlined in Section 12 of the appropriate Econoline Service Manual. 6. Recharge the A/C system as outlined in Section 12 of the appropriate Econoline Service Manual. NOTE: IN EXTREME CASES WHEN THE ABOVE PROCEDURE DOES NOT COMPLETELY FIX THE CONCERN, ATTACH A FINE SCREEN 13 mm (1/2") DOWNSTREAM OF THE EVAPORATOR CORE TO CATCH FLYING DROPLETS OF CONDENSATE. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-12-14 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961515A Modify Evaporator Case 1.1 Hr. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 961515 > Jul > 96 > A/C - Water Leaks On Passenger Side Floor > Page 7670 DEALER CODING CONDITION BASIC PART NO. CODE 19850 55 OASIS CODES: 110000, 208000, 208300, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Page 7671 Evaporator Case: Service and Repair Rear Heater/Air Installation REMOVE 1. Remove the third, fourth and fifth bench seats (if equipped). 2. Remove the left rear lower and upper trim panels, left lower front trim panel and the left center bolster trim panel (if equipped). 3. Discharge the air conditioning refrigerant system following the recommended service procedures, if equipped with auxiliary air conditioning. 4. Working under the vehicle disconnect the heater tubes to the heater water hoses connected to the auxiliary unit. Plug the heater hoses. 5. Cap the condenser lines and fittings. 6. Disconnect the main wiring harness and vacuum line to the auxiliary heater and air conditioner assembly. 7. If equipped, remove the mounting screws from the auxiliary heater and air conditioner assembly vertical duct. Lift the duct into the headliner and remove by pulling down and away from the auxiliary case assembly. 8. Lift the auxiliary heater and air conditioner assembly out of the vehicle away from the sheet metal to clear the alignment pin, while guiding the heater water hoses out from below the underbody. INSTALL 1. Place the auxiliary heater and air conditioner assembly into the vehicle while guiding the heater water hoses and air conditioner lines through the holes in the floor panel. 2. Make sure that the heater water hoses, air conditioner lines and drain seals are positioned properly. 3. Align the auxiliary heater and air conditioner assembly with the dowel alignment pin. Install the two auxiliary heater and air conditioner assembly mounting screws. 4. Place the vertical duct (if equipped) into its mounting position and install the mounting screw. 5. Connect the main wiring harness and vacuum line to the auxiliary heater and air conditioner assembly. 6. Connect the evaporator to compressor suction line (19867) and the condenser to evaporator tube (19835) to the underbody air conditioner lines. 7. Connect the heater tubes under the vehicle to the heater water hose connected to the auxiliary unit. 8. Fill the cooling system to specification and check for coolant leaks. 9. Leak-test, evacuate and charge the refrigerant system following the recommended service procedures, if equipped with auxiliary air conditioning. 10. Install the left rear lower and upper trim panels, left lower front trim panel and the left center bolster trim panel (if equipped). 11. Install the third, fourth and fifth bench seats (if equipped). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures Evaporator Core: Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures > Page 7676 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures > Page 7677 Evaporator Core: Technical Service Bulletins A/C Evaporator Core - On Vehicle Leak Test Requirement Article No. 95-13-1 07/03/95 ^ AIR CONDITIONING - EVAPORATOR CORE - "ON-VEHICLE" LEAK TEST REQUIRED FOR WARRANTY CLAIM ^ AIR CONDITIONING - "ON-VEHICLE" EVAPORATOR CORE LEAK TEST REQUIRED FOR WARRANTY CLAIM FORD: 1992-93 FESTIVA 1992-94 TEMPO 1992-95 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1992 MARK VII 1992-94 CAPRI, TOPAZ 1992-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-95 MARK VIII 1995 MYSTIQUE LIGHT TRUCK: 1992-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F-150-350 SERIES, F-47, RANGER 1993-95 VILLAGER 1995 WINDSTAR This TSB article is being republished in its entirety to correct the referenced Step for the cleaning procedure. ISSUE: An "on-vehicle" air conditioning evaporator core leak test is required before replacing any A/C evaporator core within the warranty period. ACTION: Perform the "on-vehicle" air conditioning evaporator core leak test before replacing the evaporator core. Refer to the following Evaporator Core Leak Test Procedure. EVAPORATOR CORE LEAK TEST PROCEDURE NOTE: ALL FITTINGS REQUIRED TO PERFORM THE LEAK TEST ARE INCLUDED IN TEST ADAPTER KIT D93L-1 9703-B OR EQUIVALENT. CAUTION: DISCONNECT THE LIQUID LINE AND SUCTION ACCUMULATOR FROM THE EVAPORATOR CORE TUBES. DO NOT LEAK TEST AN EVAPORATOR CORE WITH THE SUCTION ACCUMULATOR ATTACHED TO THE CORE TUBES. REFRIGERANT OUTGASSING FROM OIL AND DESICCANT IN THE ACCUMULATOR WILL INDICATE A FALSE LEAK CONDITION. 1. Verify that the manifold gauge set is capable of holding vacuum. a. Connect the RED and BLUE hoses together using a 1/4" (6.35 mm) flare coupling. b. Connect the gauge set YELLOW hose to a known good vacuum pump. c. Turn the vacuum pump ON and open both gauge set valves. d. Operate the vacuum pump for 1 minute and close both gauge set valves. The low side gauge should indicate approximately 30" of vacuum. e. Allow the gauge set, with vacuum applied, to sit for at least 30 minutes. f. If the gauge reading drops during that time, the gauge set hose connections, gauges, or valves are leaking and should be repaired before proceeding with the leak test. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures > Page 7678 2. Clean the evaporator core tube fittings. a. For threaded connections, wipe any dirt or debris from the sealing surfaces with a clean lint-free rag. b. If the evaporator core tube fittings are the female Spring Lock design, check the inside of each fitting for scratches, corrosion, or debris from deteriorated 0-rings. c. If scratches, corrosion, or debris are found, the leak test results may not be accurate unless the fitting is properly cleaned. Refer to Step 3 for cleaning procedure. 3. Clean the Spring Lock fittings as follows: a. Remove any surface residue from the inside of the female Spring Lock Coupling by polishing with 400 grit emery cloth or equivalent. b. Polish the female surface by using a twisting motion so that any scratches made will not cross the 0-ring sealing surface. See Figure 1. c. Perform additional polishing of surface using 600 grit emery cloth or equivalent. d. Remove all residue from the polishing operations by wiping the fittings with a lint-free rag. e. Connect the appropriate test fittings from Test Adapter Kit D93L-19703-B, or equivalent, to the evaporator tube connections. 5. Connect the RED and BLUE hoses from the manifold gauge set to the test fittings on the evaporator core. Connect the YELLOW hose to a known quality vacuum pump. NOTE: THE AUTOMATIC SHUTOFF VALVES ON SOME GAUGE SET HOSES DO NOT OPEN WHEN CONNECTED TO THE TEST FITTINGS. IF AVAILABLE, USE HOSES WITHOUT SHUTOFF VALVES. IF HOSES WITH SHUTOFF VALVES ARE USED, CHECK TO BE SURE THE VALVE OPENS WHEN ATTACHED TO THE TEST FITTINGS OR INSTALL AN ADAPTER WHICH WILL ACTIVATE THE VALVE. THE TEST IS NOT VALID IF THE SHUTOFF VALVE DOES NOT OPEN, ONLY THE HOSE WILL BE TESTED. 6. Open both gauge set valves and start the vacuum pump. a. Turn the A/C system blower on low to allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 30" Hg. The 45 minute evacuation is necessary to remove any refrigerant from oil left in the evaporator core. b. If the refrigerant is not completely removed from the oil, outgassing will occur and degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 30" Hg when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before replacing the evaporator core. 8. The following information is helpful in determining if a leak is present. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures > Page 7679 ^ If the low pressure gauge reading rises 10 or more inches of vacuum from the 30" position in 10 minutes, a leak is indicated. ^ If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. ^ If a small amount of vacuum is lost, operate the vacuum pump with the gauge valves open for an additional 30 minutes with the system blower on low to remove any remaining refrigerant from the oil in the evaporator core. Then, recheck for loss of vacuum as outlined. ^ If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum loss. NOTE: ALWAYS REMEMBER THAT A LEAKING FITTING, GAUGE SET OR HOSE CONNECTION WILL APPEAR AS A LEAKING EVAPORATOR CORE. 9. If the evaporator core does leak, as verified by the above procedure, install a new evaporator core. Follow the appropriate Service Manual procedure. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-10-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 290000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core: Service and Repair Front REMOVAL AND INSTALLATION 1. Discharge refrigerant from air conditioning system. 2. Disconnect and remove auxiliary battery, if equipped. 3. Disconnect electrical connector and vacuum hoses from Manifold Absolute Pressure (MAP) sensor. 4. Disconnect evaporator outlet line from suction accumulator/drier. 5. Remove screw attaching condenser to evaporator tube, then disconnect condenser to evaporator tube from inlet. 6. Remove support bracket by removing bolt from fender apron extension and two screws from evaporator case. 7. Remove evaporator cover screws and cover. Fig. 11 Evaporator Core Replacement 8. Remove evaporator core and seal assembly, Fig. 11. 9. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front > Page 7682 Evaporator Core: Service and Repair Rear Evaporator Core (Rear) A/C Evaporator Expansion Valve And Core REMOVAL 1. Remove the auxiliary heater and air conditioning assembly. 2. Remove the four screws from the A/C evaporator case cover (19B735) and remove the A/C evaporator case cover. 3. Remove the A/C evaporator core (19860) and A/C evaporator core seal (19A672). INSTALLATION 1. Install the A/C evaporator core and A/C evaporator core seal into the auxiliary heater and air conditioner assembly, making sure to align the A/C evaporator core seal in the side of the A/C evaporator case (19897). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front > Page 7683 2. Place the A/C evaporator case cover into its mounting position and install the four mounting screws. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Expansion Block/Orifice Tube: Locations A/C Orifice Tube The A/C evaporator core orifice is located in the A/C evaporator core inlet tube. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 7687 Expansion Block/Orifice Tube: Service and Repair A/C Orifice Tube Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 7688 Fig. 2 Spring lock coupling disconnect & connect Removal 1. Discharge refrigerant from system. 2. Disconnect and cap liquid line from evaporator core inlet tube. 3. Pour a small amount of refrigerant oil into inlet tube to lubricate orifice tube O-rings and inlet tube. 4. Using tool D80L-19990-A or equivalent, engage with the two tangs on the orifice tube. CAUTION: Do not twist or rotate the fixed orifice tube in the evaporator core inlet tube, as it may break off. 5. Hold T-handle of removal tool to prevent it from turning, and run nut down against evaporator core tube until orifice tube is pulled from inlet tube. 6. If the A/C Evaporator Core Orifice breaks in tube, it must be removed from the tube with Broken Orifice Tube Extractor D80L-19990-B. 7. To remove a broken Orifice Tube, insert the screw end of the Extractor Tool into the tube and thread the screw end of the tool into the brass tube in the center of the orifice body. Then pull the orifice from the tube. 8. If only the brass tube is removed in step 7, insert the screw end of the extractor tool into the orifice body. Then pull the body from the tube. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 7689 Installation 1. Lubricate the O-rings on the A/C Evaporator cor orifice liberally with clean refrigerant oil. 2. Place the orifice in the remover/replacer tool and insert into the evaporator tube until the orifice is seated at the stop. 3. Remove the tool from the orifice. 4. After checking the condenser to evaporator tube coupling end for a missing or damaged spring, install two new O-rings lubricated with clean refrigerant oil onto the male fitting. Insert the male fitting into the inlet tube until the spring lock coupling is fully engaged. 5. Leak test, evacuate and charge system. 6. Check system for proper operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations A/C Evaporator Valve And Core Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page 7693 Expansion Valve: Description and Operation REAR AUXILIARY HEATER AND A/C Thermostatic Expansion Valve PURPOSE An A/C evaporator expansion valve (19849) automatically regulates the flow of refrigerant into the A/C evaporator core (19860) in the auxiliary heater and air conditioner assembly. It also is the dividing point in the system between high and low pressure refrigerant. OPERATION The temperature sensing bulb, clamped to the suction (outlet) tube on the A/C evaporator core, measures the temperature of the refrigerant in the suction tube and transmits the temperature variation to the A/C evaporator expansion valve. This temperature variation regulates refrigerant flow to the A/C evaporator core. When the bulb senses a high temperature, the A/C evaporator expansion valve opens and floods refrigerant through the A/C evaporator core. When the bulb senses a low temperature, the A/C evaporator expansion valve starts closing to shutoff the refrigerant to the A/C evaporator core. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page 7694 Expansion Valve: Service and Repair A/C Evaporator Expansion Valve And Core REMOVAL 1. Remove the A/C evaporator core (19860) and A/C evaporator core seal (19A672). 2. Using a backup wrench to prevent damage, disconnect the air conditioner liquid jumper line tube-O connection from the A/C evaporator expansion valve (19849). 3. Using a backup wrench to prevent damage, disconnect the A/C evaporator expansion valve from the inlet tube-O connection. Remove the A/C evaporator expansion valve. INSTALLATION 4. For installation, follow removal steps in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - On Car Pressure Test For Warranty Claim Heater Core: Technical Service Bulletins Heater Core - On Car Pressure Test For Warranty Claim Article No. 97-19-11 09/15/97 COOLING SYSTEM - "ON-VEHICLE" HEATER CORE PRESSURE TEST REQUIRED FOR WARRANTY CLAIM FORD: 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-98 ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: An "On-Vehicle" heater core pressure test is required before replacing any heater core within the warranty period. ACTION: Perform the "On-Vehicle" heater core pressure test by referring to the following heater core leak test procedure. HEATER CORE LEAK TEST PROCEDURE Use the heater core pressure test to determine if the heater core is leaking. Symptoms associated with a leaking heater core include: ^ Engine coolant leaking into the passenger compartment ^ Engine coolant blown onto the windshield during defrost operation ^ Engine coolant odor inside the passenger compartment 1. Partially drain cooling system. 2. Disconnect both heater core hoses. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - On Car Pressure Test For Warranty Claim > Page 7699 3. Attach two (2) pieces of heater hose to the heater core inlet and outlet tubes and clamp (Figure 1). 4. Install Plug (part of 014-R1072) into one (1) heater hose and clamp (Figure 1). 5. Fill heater core and hoses with water. 6. Install Adapter (part of 0144-R1072) into other heater hose and clamp (Figure 1). 7. Attach Radiator/Heater Core Pressure Tester (014-R1072) to Adapter (part of 014-R1072) (Figure 1). 8. Close the bleed valve and the tester and pump air into the heater core until 241 kPa (35 psi) is reached on the tester gauge. 9. Observe the gauge after 3 minutes. The pressure should not drop. If the pressure does drop, there is a leak. Check the hose connections and retest if you find a leak. 10. Replace heater core if pressure drops and hose connections do not leak. 11. Do not replace heater core if pressure does not drop. Pressure test engine cooling system for leaks elsewhere. 12. Reconnect heater core and refill cooling system after all necessary repairs. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208999, 290000, 402000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Auxiliary (Rear) Heater Core: Service and Repair Auxiliary (Rear) Heater Core (Rear) REMOVE 1. Remove the third, fourth and fifth bench seats (if equipped). 2. Remove the left center bolster trim panel, left lower front trim panel, left rear lower and upper trim panels (if equipped). 3. Remove the six mounting screws and remove the heater core cover (18B300). 4. Clamp off the heater water hoses (18472) that connect to the heater core (18476) to prevent coolant from spilling when the heater core is removed. 5. Loosen the clamps that secure the heater water hoses to the heater core and disconnect the heater core from the heater water hoses. 6. Remove the heater core. 7. Remove the heater core case seal (18658) from the heater core. INSTALL 1. Install the heater core case seal onto the heater core. 2. Connect the heater core to the heater water hoses, making sure to install the inlet and outlet heater water hoses in their proper positions. 3. Tighten the inlet and outlet clamps. 4. Unclamp the heater core. 5. Place the heater core and seal into the auxiliary heater and air conditioner assembly. 6. Install the heater core cover and six mounting screws. 7. Fill the cooling system to specification and check for leaks. 8. Install the left lower and upper trim panels, left lower front trim panel and the left center bolster trim panel (if equipped). 9. Install the third, fourth and fifth bench seats (if equipped). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Auxiliary (Rear) > Page 7702 Heater Core: Service and Repair Main (Front) REMOVAL AND INSTALLATION 1. Drain cooling system. 2. Remove the heater water hoses from the heater core in the engine compartment using Quick Disconnect tool T85T-18539-AH, and plug hoses. 3. Remove modesty panel which runs along the lower edge of the instrument panel (04320). Fig. 7 Heater Core Replacement 4. Remove the six screws from the heater core cover (18B300) Fig. 7. located on both sides of the heater assembly case. 5. Remove heater core cover. 6. Remove heater core and heater core case seal (18658) from the heater assembly. 7. Reverse procedure to install, refill cooling system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7707 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7708 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7709 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7710 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7711 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7712 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7713 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7714 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7715 Refrigerant: Technical Service Bulletins A/C - Release of R134a Fluorescent Dye Article No. 94-26-6 12/26/94 AIR CONDITIONING - RELEASE OF R-134A FLUORESCENT TRACER DYE - FOR 1992 TAURUS, R-134A VEHICLES ONLY - SERVICE TIP FORD: 1992-95 TAURUS 1994-95 ASPIRE, CROWN VICTORIA, ESCORT, MUSTANG, PROBE, THUNDERBIRD 1994 TEMPO 1995 CONTOUR LINCOLN-MERCURY: 1993-95 MARK VIII 1994-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1994 CAPRI, TOPAZ 1995 MYSTIQUE LIGHT TRUCK: 1994-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995 WINDSTAR ISSUE: Ford Motor Company has approved an R-134a Fluorescent Tracer Dye (Rotunda Part, 112-ROO40) for use in checking R-134a A/C systems for refrigerant leaks. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7716 ACTION: When leak checking an R-134a system, install the 112-R0040 dye using a Rotunda Dye lnjector (164-R2610). Use the procedures in Figure 1 when leak checking. This method of leak detection is an approved alternate to electronic leak detection and vacuum decay leak detection. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications With Front A/C A/C Refrigerant Capacity (Front Only) ................................................................................................. ...................................................................... 52 oz With Front and Rear A/C A/C Refrigerant Capacity (Front and Rear Only) ........................................................................................................................................................ 64 oz Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7719 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ....................................................................... R-134a Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 7724 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 7725 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 7726 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > Customer Interest: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure Refrigerant Oil: Customer Interest A/C - Insufficient Cooling/ Compressor Failure Article No. 97-10-5 05/12/97 ^ AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL ^ AIR CONDITIONING - LACK OF COOLING - INSUFFICIENT AMOUNT OF REFRIGERANT OIL MAY CAUSE COMPRESSOR FAILURE FORD: 1994-97 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1994-97 COUGAR LIGHT TRUCK: 1993-96 BRONCO 1993-97 F-150-350 SERIES, F-47 1994-95 ECONOLINE 1994-96 VILLAGER 1994-97 AEROSTAR, EXPLORER, RANGER 1995-96 WINDSTAR 1997 MOUNTAINEER This TSB article is being republished in its entirety to include 1997 F-Series. ISSUE: Some vehicles may exhibit air conditioner compressor failure due to an insufficient amount of refrigerant oil in the system. ACTION: Whenever service is required on the A/C system, add the appropriate refrigerant oil to the system. Refer to the following Service Procedure for details. NOTE: USE MOTORCRAFT YN-9 REFRIGERANT COMPRESSOR OIL FOR 1993 MODELS EQUIPPED WITH AN R-12 SYSTEM. FOR 1994 AND LATER MODELS USING AN R-134a SYSTEM, USE MOTORCRAFT YN-12-B POLYALKYLENE GLYCOL (PAG) REFRIGERANT COMPRESSOR OIL. SERVICE PROCEDURE 1. Remove all refrigerant from the A/C system using the appropriate R-12 or R-134a refrigerant recovery equipment following the manufacturer's operating instructions. 2. Service the A/C system as required. 3. Check for Modification Label indicating additional refrigerant oil is already in place. 4. If no label was found, add additional clean refrigerant oil (over and above the amount of oil required for the system being serviced). The oil may be poured directly into the accumulator assembly or it may be injected by the refrigerant charging station, if so equipped. 5. Recharge the A/C system using the appropriate refrigerant. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > Customer Interest: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure > Page 7735 Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) 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. PART NUMBER PART NAME YN-9 Refrigerant Oil (R-12 Systems) YN-12-B Refrigerant Oil (R-134a Systems) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity Refrigerant Oil: All Technical Service Bulletins A/C - Refrigerant Oil Refill Capacity Article No. 97-15-5 07/21/97 AIR CONDITIONING - OIL REFILL CAPACITY CHART - SERVICE TIP FORD: 1994 TEMPO 1994-97 ASPIRE, PROBE, THUNDERBIRD 1994-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1994 CAPRI, TOPAZ 1994-97 COUGAR 1994-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1994-96 BRONCO 1994-97 AEROSTAR 1994-98 ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: This TSB article will provide an easy and quick reference chart for determining the correct amount of refrigerant oil to use when servicing an A/C system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity > Page 7741 ACTION: Refer to Figure 1 to determine how much refrigerant oil is needed to service an A/C system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure Refrigerant Oil: All Technical Service Bulletins A/C - Insufficient Cooling/ Compressor Failure Article No. 97-10-5 05/12/97 ^ AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL ^ AIR CONDITIONING - LACK OF COOLING - INSUFFICIENT AMOUNT OF REFRIGERANT OIL MAY CAUSE COMPRESSOR FAILURE FORD: 1994-97 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1994-97 COUGAR LIGHT TRUCK: 1993-96 BRONCO 1993-97 F-150-350 SERIES, F-47 1994-95 ECONOLINE 1994-96 VILLAGER 1994-97 AEROSTAR, EXPLORER, RANGER 1995-96 WINDSTAR 1997 MOUNTAINEER This TSB article is being republished in its entirety to include 1997 F-Series. ISSUE: Some vehicles may exhibit air conditioner compressor failure due to an insufficient amount of refrigerant oil in the system. ACTION: Whenever service is required on the A/C system, add the appropriate refrigerant oil to the system. Refer to the following Service Procedure for details. NOTE: USE MOTORCRAFT YN-9 REFRIGERANT COMPRESSOR OIL FOR 1993 MODELS EQUIPPED WITH AN R-12 SYSTEM. FOR 1994 AND LATER MODELS USING AN R-134a SYSTEM, USE MOTORCRAFT YN-12-B POLYALKYLENE GLYCOL (PAG) REFRIGERANT COMPRESSOR OIL. SERVICE PROCEDURE 1. Remove all refrigerant from the A/C system using the appropriate R-12 or R-134a refrigerant recovery equipment following the manufacturer's operating instructions. 2. Service the A/C system as required. 3. Check for Modification Label indicating additional refrigerant oil is already in place. 4. If no label was found, add additional clean refrigerant oil (over and above the amount of oil required for the system being serviced). The oil may be poured directly into the accumulator assembly or it may be injected by the refrigerant charging station, if so equipped. 5. Recharge the A/C system using the appropriate refrigerant. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure > Page 7746 Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) 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. PART NUMBER PART NAME YN-9 Refrigerant Oil (R-12 Systems) YN-12-B Refrigerant Oil (R-134a Systems) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 961015 > May > 96 > Air Conditioning - Oil Refill And Charge Service Tip Refrigerant Oil: All Technical Service Bulletins Air Conditioning - Oil Refill And Charge Service Tip Article No. 96-10-15 05/06/96 AIR CONDITIONING - REFRIGERANT OIL REFILL AND CHARGE SERVICE TIP LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The refrigerant oil and charge levels for 1995-96 Econolines have changed. ACTION: When servicing or installing Add-On or Aftermarket A/C systems on these vehicles, it is important to note the proper refrigerant and oil levels to prevent A/C system failure. Refer to the Capacity Chart for correct refill levels. PART NUMBER PART NAME YN-16 R-134a Refrigerant F2AZ-19577-AC Refrigerant Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 95512 > Mar > 95 > A/C - Adding Refrigerant Oil Service Tip Refrigerant Oil: All Technical Service Bulletins A/C - Adding Refrigerant Oil Service Tip Article No. 95-5-12 03/13/95 AIR CONDITIONING - ADDING REFRIGERANT OIL - SERVICE TIP FORD: 1990-93 FESTIVA 1990-94 TEMPO 1990-95 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-95 ASPIRE LINCOLN-MERCURY: 1990-92 MARK VII 1990-94 TOPAZ 1990-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-94 CAPRI 1993-95 MARK VIII MERKUR: 1990 SCORPIO LIGHT TRUCK: 1990 BRONCO II 1990-95 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-95 EXPLORER 1993-95 VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-91 C SERIES, CL-CLT-9000 SERIES 1990-95 CARGO SERIES, F & B SERIES, L SERIES ISSUE: Current repair procedures do not advise on the addition of refrigerant oil to the A/C system when a minor repair is made. ACTION: Add 0.06 L (2 oz) of the proper type new refrigerant oil to the system,. before recharging, when servicing concerns that do not require major component replacement. Repairs considered minor are: O-ring leaks, charge port leaks, Pressure Relief Valve (PRV) leaks, compressor shaft seal leaks, hose leaks, etc. Remember to use polyalkylene glycol (PAG) oil with R-134a systems and mineral oil with R-12 systems. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity Refrigerant Oil: All Technical Service Bulletins A/C - Refrigerant Oil Refill Capacity Article No. 97-15-5 07/21/97 AIR CONDITIONING - OIL REFILL CAPACITY CHART - SERVICE TIP FORD: 1994 TEMPO 1994-97 ASPIRE, PROBE, THUNDERBIRD 1994-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1994 CAPRI, TOPAZ 1994-97 COUGAR 1994-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1994-96 BRONCO 1994-97 AEROSTAR 1994-98 ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: This TSB article will provide an easy and quick reference chart for determining the correct amount of refrigerant oil to use when servicing an A/C system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity > Page 7760 ACTION: Refer to Figure 1 to determine how much refrigerant oil is needed to service an A/C system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 961015 > May > 96 > Air Conditioning - Oil Refill And Charge Service Tip Refrigerant Oil: All Technical Service Bulletins Air Conditioning - Oil Refill And Charge Service Tip Article No. 96-10-15 05/06/96 AIR CONDITIONING - REFRIGERANT OIL REFILL AND CHARGE SERVICE TIP LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The refrigerant oil and charge levels for 1995-96 Econolines have changed. ACTION: When servicing or installing Add-On or Aftermarket A/C systems on these vehicles, it is important to note the proper refrigerant and oil levels to prevent A/C system failure. Refer to the Capacity Chart for correct refill levels. PART NUMBER PART NAME YN-16 R-134a Refrigerant F2AZ-19577-AC Refrigerant Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 95512 > Mar > 95 > A/C - Adding Refrigerant Oil Service Tip Refrigerant Oil: All Technical Service Bulletins A/C - Adding Refrigerant Oil Service Tip Article No. 95-5-12 03/13/95 AIR CONDITIONING - ADDING REFRIGERANT OIL - SERVICE TIP FORD: 1990-93 FESTIVA 1990-94 TEMPO 1990-95 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-95 ASPIRE LINCOLN-MERCURY: 1990-92 MARK VII 1990-94 TOPAZ 1990-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-94 CAPRI 1993-95 MARK VIII MERKUR: 1990 SCORPIO LIGHT TRUCK: 1990 BRONCO II 1990-95 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-95 EXPLORER 1993-95 VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-91 C SERIES, CL-CLT-9000 SERIES 1990-95 CARGO SERIES, F & B SERIES, L SERIES ISSUE: Current repair procedures do not advise on the addition of refrigerant oil to the A/C system when a minor repair is made. ACTION: Add 0.06 L (2 oz) of the proper type new refrigerant oil to the system,. before recharging, when servicing concerns that do not require major component replacement. Repairs considered minor are: O-ring leaks, charge port leaks, Pressure Relief Valve (PRV) leaks, compressor shaft seal leaks, hose leaks, etc. Remember to use polyalkylene glycol (PAG) oil with R-134a systems and mineral oil with R-12 systems. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications With Front A/C Refrigerant Oil System Capacity ......................................................................................................... ......................................................................... 7.0 oz With Front and Rear A/C Refrigerant Oil System Capacity ......................................................................................................... ....................................................................... 10.0 oz Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7771 Refrigerant Oil: Fluid Type Specifications Polyalkylene Glycol (PAG) ........................................................................................................................................ WSH-M1C231-B Motorcraft YN-12c Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay Blower Motor Relay: Locations Auxiliary Blower Relay Full Body View (Part 1 Of 3) The Auxiliary Blower Motor Relay is located at the left rear corner of the vehicle, above wheel well. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 7777 Blower Motor Relay: Locations Auxiliary High Blower Motor Relay Full Body View (Part 3 Of 3) The Auxiliary High Blower Motor Relay is located at the left rear corner of the vehicle, above wheel well. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Relay > Page 7778 Blower Motor Relay: Locations Front Blower Relay Engine Compartment View The Blower Motor Relay is located at the LH front of engine compartment, near starter relay. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay Auxiliary Blower Motor Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Auxiliary Blower Motor Relay > Page 7781 Auxiliary High Blower Motor Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams Auxiliary A/C-Heater Blower Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary Blower Motor Switch: Testing and Inspection Auxiliary Auxiliary A/C-Heater Blower Switch - Component Testing Procedure Auxiliary A/C-Heater Blower Switch - Terminal Locations Auxiliary A/C-Heater Blower Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary > Page 7788 Blower Motor Switch: Testing and Inspection Front Blower Switch Front Blower Switch - Component Testing Procedure Front Blower Switch - Terminal Locations Front Blower Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Auxiliary > Page 7789 Blower Motor Switch: Testing and Inspection Rear Auxiliary Rear Auxiliary Blower Switch - Component Testing Procedure Rear Auxiliary Blower Switch - Terminal Locations Rear Auxiliary Blower Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Testing and Inspection > Page 7790 Blower Motor Switch: Service and Repair Rear Air Control Switch View REMOVAL AND INSTALLATION 1. Using a screwdriver, carefully pry the rear control assembly out of the headliner. 2. Disconnect the electrical connector from the heater blower motor switch (18578). 3. If necessary, remove the knob from the heater blower motor switch and remove the switch from the rear control unit. 4. For installation, follow removal steps in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations The high pressure service port is located on the A/C compressor to condenser discharge line. The low pressure service port is located in the evaporator to compressor suction line. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 7794 Service Port HVAC: Description and Operation The A/C service port valves on R-134a systems are of the one-piece design. The top portion of the fitting is aluminum and is threaded into a steel body on the suction accumulator/drier or on the refrigerant line and sealed with an O-ring. Two special service tools have been developed to aid in servicing of the access gauge port valves. They are the high side A/C fitting socket tool No. D94L-19703-A, or equivalent and low side A/C fitting socket tool No. D94L-19703-B, or equivalent. The high side fitting is the largest of the two valves. Both valves require special adapters to attach service equipment to the A/C system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver side air bag module connector. 5. Connect Rotunda Air Bag Simulator 105-00010 or equivalent to vehicle harness at top of steering wheel. 6. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. REACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute for backup power supply to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. Reconnect driver air bag module connector. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten nut and washer assemblies 4-6 Nm (36-53 lb-in). 4. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 5. Prove out system. Refer to System Prove Out Procedure under Testing and Inspection / Procedures / Diagnostic Strategies. WARNING: THE AIR BAG SIMULATOR(S) MUST BE REMOVED AND THE DRIVER SIDE AIR BAG MODULE RECONNECTED FOR THE SYSTEM TO BE REACTIVATED. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 7801 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Are center sensor and frame rail sensor connected and mounted to vehicle? ........................................................................................................... [ ] 2. Is right cowl side sensor connected and mounted to vehicle? ................................................................................................................................... [ ] 3. Is gray three-way connector at base of steering column connected? ........................................................................................................................ [ ] 4. Is air bag or air bag simulator connected? ...................................................................................... .......................................................................... [ ] 5. Is air bag diagnostic monitor connected? ........................................................................................ ......................................................................... [ ] 6. Is vehicle battery connected? .......................................................................................................... .......................................................................... [ ] Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag Modules - Discolored/Marred Covers Air Bag: Technical Service Bulletins Air Bag Modules - Discolored/Marred Covers ARTICLE NO. 95-21-1 10/23/95 SUPPLEMENTAL RESTRAINT SYSTEM - AIR BAG MODULES - DISCOLORED OR MARRED COVERS - PAINTING RESTRICTIONS FORD: 1988-94 TEMPO 1990-96 CROWN VICTORIA, MUSTANG, TAURUS 1992-96 PROBE 1994-96 ASPIRE, ESCORT, THUNDERBIRD 1995-96 CONTOUR LINCOLN-MERCURY: 1988-96 CONTINENTAL 1989-94 TOPAZ 1990-92 MARK VII 1990-96 GRAND MARQUIS, SABLE, TOWN CAR 1991-94 CAPRI 1993-96 MARK VIII 1994-96 COUGAR, TRACER 1995-96 MYSTIQUE LIGHT TRUCK: 1992-96 AEROSTAR, ECONOLINE 1994-96 BRONCO, F-150-350 SERIES, VILLAGER 1995-96 EXPLORER, RANGER, WINDSTAR This TSB is being republished in its entirety to include 1994-96 vehicles. ISSUE: The covers of the driver and passenger air bag modules MUST NOT be repainted for any reason. Any applied paint may damage the cover material. This could affect air bag performance during deployment and may increase the risk of injury during a collision. ACTION: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag Modules - Discolored/Marred Covers > Page 7806 Air Bag Modules with damaged or marred deployment covers MUST BE COMPLETELY REPLACED - NOT REPAINTED. Refer to the Dealer Master Parts Catalog for correct parts usage. Air bag modules are on the Mandatory Return List and must be returned to the Warranty Parts Return Center. Refer to Figure 1. Refer to TSB 91-9-1 for air bag return information. OTHER APPLICABLE ARTICLES: 91-9-1 SUPERSEDES: 92-24-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 107000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 7807 Air Bag: Specifications Driver Air Bag Module-to-Steering Wheel Nuts ................................................................................................................................ 4-6 Nm (36-53 Lb-In) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 7808 Air Bag: Description and Operation The driver side air bag module is mounted in the center of the steering wheel. The module consists of: - Inflator - Airbag - Mounting plate and retainer ring - Steering wheel trim cover Inflator When the sensors close, signaling a crash, electric current flows to the air bag inflator. Inside the inflator, an igniter converts the electrical signal to thermal (heat) energy, causing the ignition of the inflator gas generant. This ignition reaction combusts the sodium azide/copper oxide gas generant in the inflator, producing nitrogen gas, which inflates the air bag. NOTE: The inflator is a component of the driver side air bag module and is not a serviceable item. The driver side air bag module is serviced as a complete assembly. Air Bag The air bag: - is constructed of neoprene coated nylon. - is 711 mm (28 inches) in diameter. - fills to a volume of 0.065 cu. m (2.3 cu.ft) in approximately 40 milliseconds. NOTE: The air bag is a component of the driver side air bag module and is not a serviceable item. The driver side air bag module is serviced as a complete assembly. Mounting Plate and Retainer Ring The mounting plate and retainer ring attach and seal the air bag assembly to the inflator. The mounting plate is also used to attach the trim cover and to mount the entire driver side air bag module to the steering wheel. NOTE: The mounting plate and retainer ring are components of the driver side air bag module and are not serviceable items. The driver side air bag module is serviced as a complete assembly. Steering Wheel Trim Cover The steering wheel trim cover is made of injection-moulded plastic and covers the air bag. When the supplemental air bag restraint system is activated, tear seams moulded into the steering wheel trim cover separate, allowing inflation of the air bag. NOTE: The steering wheel trim cover is a component of the driver side air bag module and is not a serviceable item. The driver side air bag module is serviced as a complete assembly. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Disposal Procedures Air Bag: Service and Repair Disposal Procedures Disposal Recommendations Several situations may arise which require some form of disposal action: scrapping a vehicle containing a deployed air bag, scrapping a vehicle with a live air bag, disposal of a live but electrically inoperative driver side air bag module or scrapping a deployed driver side air bag module. Disposal recommendations for these situations are shown in the following chart and described in detail below. AIR BAG DISPOSAL RECOMMENDATIONS 1. Vehicle to be scrapped - live air bags: - Electrically deploy using applicable deployment procedure. 2. Vehicle to be scrapped - deployed air bags: - Scrap vehicle in the usual manner. 3. Air bag module replaced - damaged but live air bags: - Package and label properly. Return to Ford. 4. Air bag module replaced - deployed air bags: - Scrap air bag in the usual manner. Deployed Air Bags To service a vehicle in which the air bag has deployed, the deployed air bag must be replaced with a new air bag. The deployed air bag can be disposed of in the same manner as any part to be scrapped. Faulty, Undeployed Air Bag In the event that a driver side air bag module is diagnosed as faulty, the faulty driver side air bag module must be replaced by a driver side air bag module. The faulty air bag CANNOT BE DISPOSED OF IN THE USUAL MANNER. It must be returned intact to Ford Motor Company for proper disposal. Return the carton to the following address for warranty claim credit: Warranty Parts Return Center 1285 S. Mill Street Plymouth, MI 48170 NOTE: All faulty live air bags have been placed on the Mandatory Return List. All discolored or damaged driver side air bag modules should be treated the same as any faulty live air bag being returned. The driver side air bag module must be packaged and shipped according to the U.S. Department of Transportation regulations. Retain packaging used for replacement driver side air bag module, including the labeling. Do not deploy air bag. Properly package the driver side air bag module in the original service replacement carton and securely tape shut. Affix Flammable Solid label and shipping exemption to package. Scrapped Vehicle Some vehicles that are damaged or inoperable to the point that service cannot be made may contain undeployed air bags. This condition could occur by side or rear impact, rollover or if the vehicle is simply past its useful lifetime. THE AIR BAGS SHOULD BE DEPLOYED USING APPROPRIATE DEPLOYMENT PROCEDURE PRIOR TO SCRAPPING VEHICLE. See: Service and Repair/Disposal Procedures Procedure 1 - Electronic Deployment With Wiring Intact This procedure is to be used in the event that a vehicle with a live air bag is to be scrapped. Scrapping a vehicle may be required due to severe damage in a non-air bag deployable accident or at the end of the vehicle's useful life. This procedure assumes that the air bag wiring remains intact; this is, no diagnostic trouble codes are indicated by the air bag indicator, the system proves out correctly and the vehicle's battery is still in place (or one has been provided). This procedure is to be performed outdoors, away from other personnel, since the deploying air bag makes a loud report upon actuation. 1. Check and clear the front seat of all loose objects. 2. Do not permit any occupants to remain inside the vehicle. 3. Open the hood and check for an operational vehicle battery. If no battery is found, supply one and connect it in the usual manner. 4. Turn the ignition switch to the RUN position and observe the air bag indicator. If the indicator illuminates for six seconds and then stops, the supplemental air bag restraint system is intact and may be deployed. Continue with Procedure 1. If a series of diagnostic trouble codes appear, go to Procedure 2 to deploy the unit. 5. Turn ignition switch to the OFF position. 6. Locate and disconnect front air bag safing sensor and bracket connector on RH cowl side. 7. Jump Circuits 611 (W/O) and 614 (GY/O) using a 152 mm (6-inch) length of bared wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Disposal Procedures > Page 7811 WARNING: MAKE SURE THERE ARE NOT OCCUPANTS IN THE VEHICLE. 8. Disconnect center air bag primary crash sensor and bracket located on the radiator support. 9. Using a 152 mm (6-inch) length of bared wire, short the 617 (PK/O) or 619 (PK/O) wire-to-ground. The air bag should deploy. If the air bag does not deploy, go to Procedure 2. 10. If successful, a loud report will be heard and the bag material will be visible in the center of the steering wheel. Allow at least 10 minutes before approaching the air bag to allow for cooling. The air bag is now inoperative and the vehicle may be scrapped in the usual manner. Procedure 2 - Remote Deployment of Air Bag This procedure is to be used in the event that a vehicle with a live air bag is to be scrapped, but the vehicle does not contain an intact wiring harness or certain supplemental air bag restraint system components are inoperative. This procedure can also be used if Step 4 or 9 of Procedure 1 was unsuccessful. 1. Remove the driver side air bag module from the vehicle. WARNING: REMOTE DEPLOYMENT IS TO BE PERFORMED OUTDOORS WITH ALL PERSONNEL AT LEAST 20 FEET AWAY TO ENSURE PERSONAL SAFETY AND DUE TO THE LOUD REPORT WHICH OCCURS WHEN DRIVER AIR BAG IS DEPLOYED. 2. Cut the two connector wires on driver side air bag module and strip 25 mm (1 inch) of insulation from the ends. Obtain two wires at least 20 feet long. Connect one end of each wire to each of the wires on driver side air bag module. 3. Place the driver side air bag module with the trim cover facing upward on a flat surface in a remote area such as a parking lot or field. WARNING: DO NOT PLACE THE DRIVER SIDE AIR BAG MODULE WITH THE TRIM COVER FACING DOWN, AS THE FORCES OF THE DEPLOYING AIR BAG MAY CAUSE IT TO RICOCHET AND CAUSE PERSONAL INJURY. 4. Remaining at least 20 feet away from the driver side air bag module, deploy it by touching the other ends of the two wires to the terminals of a 12-volt vehicle battery. 5. If successful, a loud report will be heard and the air bag material will be visible. Allow at least 10 minutes before approaching the air bag to allow for cooling. The air bag is now deployed and may be scrapped in the usual manner. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Disposal Procedures > Page 7812 Air Bag: Service and Repair Removal and Installation Removal NOTE: If the air bag did not deploy in an accident it may not have been needed. Complete all diagnosis procedures before replacing the air bag diagnostic monitor. 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY POSITIVE CABLE MUST BE DISCONNECTED FOR ONE MINUTE PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. 2. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 3. Disconnect the electrical connector on driver side air bag module from connector on air bag sliding contact. 4. Remove driver side air bag module. WARNING: AFTER REMOVAL, PLACE AIR BAG MODULE ON BENCH WITH TRIM COVER FACING UP. Installation 1. Fill out the traceability postcard supplied with the new driver side air bag module and return it to Ford Motor Company. Note the diagnostic trouble code. 2. Connect wiring connector of the driver side air bag module to connector on the air bag sliding contact. 3. Position driver side air bag module to steering wheel and secure with four nut and washer assemblies. Tighten to 4-6 Nm (36-53 lb-in). 4. Connect battery positive cable. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Disposal Procedures > Page 7813 NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 5. Prove out system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Full Body View (Part 2 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7817 The Air Bag Module is located behind LH (Driver's Side) side of instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7818 Air Bag Control Module: Diagrams Air Bag Module (C209) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7819 Air Bag Module (C208) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7820 Air Bag Control Module: Description and Operation The air bag diagnostic monitor continually monitors all supplemental air bag restraint system components and wiring connections for possible faults in the system. If the air bag diagnostic monitor detects a fault in the supplemental air bag restraint system when the ignition switch is in the RUN position, a diagnostic trouble code will be displayed on the air bag indicator, located in the instrument cluster. Performing system diagnostics is the main purpose of the air bag diagnostic monitor. The air bag diagnostic monitor does not deploy the air bag in the event of a crash. The center and right rear air bag sensors are "hard wired" to the air bag, therefore, the center and right rear front primary crash sensors and RH cowl side panel air bag safing sensor determine when to deploy the air bag. FEATURES AND FUNCTIONS - The air bag diagnostic monitor illuminates the air bag indicator for approximately six seconds when the ignition switch is in the RUN position and then turns the indicator off. This shows that the air bag indicator is operational. If the air bag indicator does not illuminate or the indicator stays on or flashes at any time, a fault has been detected by the air bag diagnostic monitor. - Diagnostic trouble codes may not be displayed for approximately 30 seconds after the ignition switch is placed in the RUN position. This is the amount of time the air bag diagnostic monitor requires to perform all tests and verify system faults, if present. - Each diagnostic trouble code (a series of flashes and pauses of the air bag indicator) represents a two-digit number. Each diagnostic trouble code is always displayed at least twice. For example, a diagnostic trouble code 32 is displayed as three flashes, followed by a one-second pause, then two flashes, followed by a three-second pause. - If a system fault is present and the air bag indicator is malfunctioning, an audible tone will be heard, indicating that system service is required. The tone is a series of five sets of five beeps. This does not indicate a diagnostic trouble code 55. If the tone is heard, the air bag indicator is inoperative and a system fault that requires service is present. - If a fault exists that makes unwanted air bag deployment possible, the air bag diagnostic monitor has an internal thermal fuse that will blow (open) automatically. This removes all power to the air bag deployment circuit. CAUTION: The thermal fuse does not blow (open) because of excessive current flowing through it. DO NOT attempt to jumper out the thermal fuse with a circuit breaker or any other type of fuse. - The air bag indicator will flash the appropriate diagnostic trouble code to indicate the suspect circuit. If the indicator is malfunctioning the tone will be heard. - Diagnostic trouble codes are prioritized numerically so if two or more different faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. - The air bag diagnostic monitor includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event the battery or battery cables are damaged in an accident before the center air bag and front air bag sensors close. The backup power supply will deplete its stored energy approximately one minute after the positive battery cable is disconnected. WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT SERVICE IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY POSITIVE CABLE AND WAIT ONE MINUTE. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7821 Air Bag Control Module: Service and Repair CAUTION: When servicing the air bag diagnostic monitor with a blown internal fuse (DTC 51), find and repair all wire damage or shorts. A blown air bag diagnostic monitor can be used to find electrical faults without replacing components unnecessarily. The diagnostic procedures are written to give safety first priority. The following steps may be taken to find the cause that initiated a blown fuse: 1. Verify the system using the old air bag diagnostic monitor and verify the wiring repairs success before proceeding. Repeat as many times as required. 2. Replace the air bag diagnostic monitor when all wire repairs are complete. 3. If the diagnostic trouble code returns after making all wiring repairs, then replace the indicated component. Removal and Installation 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY POSITIVE CABLE MUST BE DISCONNECTED FOR ONE MINUTE PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 mites or more to relearn the strategy. 2. Locate air bag diagnostic monitor beneath and to the left of the steering column and disconnect the two connectors. 3. Depress tabs retaining air bag diagnostic monitor to air bag monitor bracket. Slide air bag diagnostic monitor off air bag monitor bracket. 4. Disconnect electrical wiring connectors to air bag diagnostic monitor. Remove air bag diagnostic monitor. 5. For installation, follow removal procedures in reverse order. Prove out system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Sliding Contact: > 9697 > Apr > 96 > Steering Wheel - Squeaks While Turning Air Bag Sliding Contact: Customer Interest Steering Wheel - Squeaks While Turning Article No. 96-9-7 04/22/96 STEERING - STEERING WHEEL "SQUEAK" WHILE TURNING - VEHICLES WITHOUT AIR BAG - 1993-94 OVER 8500 GVW AND 1995 E-350 STRIPPED CHASSIS AND CUTAWAY LIGHT TRUCK: 1993-94 ECONOLINE 1995 E-350 ISSUE: A "squeak" noise while turning the steering wheel may occur on some vehicles. This may be caused by contact between the clockspring's rotor and housing within the steering wheel assembly. ACTION: Replace the clockspring assembly with a brush assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE REMOVAL 1. Center front wheels to the straight ahead position. 2. Disconnect the battery ground cable. 3. Unsnap the steering wheel pad horn switch from the steering wheel by grasping the sides of the steering wheel pad horn switch and pulling toward yourself (Figure 1). 4. Disconnect the horn/speed control wire harness connector from the contact assembly. Remove and discard the steering wheel pad horn switch from the steering wheel. Keep the retaining screw (390345-S36 if necessary to replace), it will be used during the installation process. 5. Remove the steering wheel retaining bolt. 6. Install Steering Wheel Puller (T67L-3600-A) and remove steering wheel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Sliding Contact: > 9697 > Apr > 96 > Steering Wheel - Squeaks While Turning > Page 7830 7. Remove the clockspring assembly and discard. INSTALLATION 1. Make sure the vehicle's front wheels are in the straight ahead position. 2. Install new wiring with new brush assembly (-90899-) by aligning the bolt on the brush to the steering column and connect the ignition cylinder, PRNDL label, and wiring harness connectors (-14A200-). Torque the retaining screw to 2-3 N.m (1.5-2.2 lb-ft) (Figure 2). 3. Position the new steering wheel (F6TZ-3600-AAA) on the steering shaft so the alignment marks are aligned. 4. Install a new steering wheel retaining bolt (N804385-S100) and tighten to 31-44 N.m (23-32 lb-ft). 5. Connect steering wheel pad horn switch speed control wire harness (-13A805-) to brush assembly connector. 6. Position steering wheel pad horn switch over steering wheel and snap into place. 7. Reconnect the battery ground cable. NOTE: WHEN THE BATTERY HAS BEEN DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE POWERTRAIN CONTROL MODULE (PCM) RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16km (10 MILES) OR MORE FOR PCM TO RELEARN THE STRATEGY. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Sliding Contact: > 9697 > Apr > 96 > Steering Wheel - Squeaks While Turning > Page 7831 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960907A Replace Clockspring With 0.5 Hr. Brush Assembly DEALER CODING CONDITION BASIC PART NO. CODE 13806 79 OASIS CODES: 107000, 203000, 303000, 702000, 702300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Sliding Contact: > 9697 > Apr > 96 > Steering Wheel - Squeaks While Turning Air Bag Sliding Contact: All Technical Service Bulletins Steering Wheel - Squeaks While Turning Article No. 96-9-7 04/22/96 STEERING - STEERING WHEEL "SQUEAK" WHILE TURNING - VEHICLES WITHOUT AIR BAG - 1993-94 OVER 8500 GVW AND 1995 E-350 STRIPPED CHASSIS AND CUTAWAY LIGHT TRUCK: 1993-94 ECONOLINE 1995 E-350 ISSUE: A "squeak" noise while turning the steering wheel may occur on some vehicles. This may be caused by contact between the clockspring's rotor and housing within the steering wheel assembly. ACTION: Replace the clockspring assembly with a brush assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE REMOVAL 1. Center front wheels to the straight ahead position. 2. Disconnect the battery ground cable. 3. Unsnap the steering wheel pad horn switch from the steering wheel by grasping the sides of the steering wheel pad horn switch and pulling toward yourself (Figure 1). 4. Disconnect the horn/speed control wire harness connector from the contact assembly. Remove and discard the steering wheel pad horn switch from the steering wheel. Keep the retaining screw (390345-S36 if necessary to replace), it will be used during the installation process. 5. Remove the steering wheel retaining bolt. 6. Install Steering Wheel Puller (T67L-3600-A) and remove steering wheel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Sliding Contact: > 9697 > Apr > 96 > Steering Wheel - Squeaks While Turning > Page 7837 7. Remove the clockspring assembly and discard. INSTALLATION 1. Make sure the vehicle's front wheels are in the straight ahead position. 2. Install new wiring with new brush assembly (-90899-) by aligning the bolt on the brush to the steering column and connect the ignition cylinder, PRNDL label, and wiring harness connectors (-14A200-). Torque the retaining screw to 2-3 N.m (1.5-2.2 lb-ft) (Figure 2). 3. Position the new steering wheel (F6TZ-3600-AAA) on the steering shaft so the alignment marks are aligned. 4. Install a new steering wheel retaining bolt (N804385-S100) and tighten to 31-44 N.m (23-32 lb-ft). 5. Connect steering wheel pad horn switch speed control wire harness (-13A805-) to brush assembly connector. 6. Position steering wheel pad horn switch over steering wheel and snap into place. 7. Reconnect the battery ground cable. NOTE: WHEN THE BATTERY HAS BEEN DISCONNECTED AND RECONNECTED, SOME ABNORMAL DRIVE SYMPTOMS MAY OCCUR WHILE THE POWERTRAIN CONTROL MODULE (PCM) RELEARNS ITS ADAPTIVE STRATEGY. THE VEHICLE MAY NEED TO BE DRIVEN 16km (10 MILES) OR MORE FOR PCM TO RELEARN THE STRATEGY. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Sliding Contact: > 9697 > Apr > 96 > Steering Wheel - Squeaks While Turning > Page 7838 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960907A Replace Clockspring With 0.5 Hr. Brush Assembly DEALER CODING CONDITION BASIC PART NO. CODE 13806 79 OASIS CODES: 107000, 203000, 303000, 702000, 702300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Technical Service Bulletins > Page 7839 Air Bag Sliding Contact: Specifications Air Bag Sliding Contact Screws ........................................................................................................... .................................................2-3 Nm (18-26 Lb-In) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Technical Service Bulletins > Page 7840 Air Bag Sliding Contact: Description and Operation The steering column assembly is an energy-absorbing type. It has two breakaway mounting points (capsules) molded into the column casting and a bendstrap that allows controlled downward movement of the steering column and wheel upon impact. The air bag sliding contact is mounted on the steering column, behind the steering wheel. The air bag sliding contact continuously transfers electrical signals from the steering column wire harness to the contact in the steering wheel for the supplemental air bag restraint system to the impact sensors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Technical Service Bulletins > Page 7841 Air Bag Sliding Contact: Adjustments 1. Disconnect the battery positive cable and wait one minute for the backup power supply energy to be depleted. WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT SERVICE IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY POSITIVE CABLE AND WAIT ONE MINUTE. 2. Make sure the vehicle's front wheels are in the straight ahead position. 3. Remove the driver side air bag module. 4. Remove the steering wheel. 5. Turn the air bag sliding contact clockwise until it stops. CAUTION: Do not apply excessive force to the air bag sliding contact. 6. Rotate the air bag sliding contact counterclockwise 2.75 turns. 7. Align the marks on the air bag sliding contact with the marks on the outer housing. 8. Install the steering wheel. 9. Install the air bag module. 10. Connect the battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 11. Verify that the air bag indicator is operative. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Center Air Bag Primary Crash Sensor-to-Radiator Support Screws ...................................................................................................10-14 Nm (7-10 Lb-Ft) Front Air Bag Primary Crash Sensor-to-Right Frame Screws ...........................................................................................................13-17 Nm (10-13 Lb-Ft) Replacement Retaining Screws .......................................................................................................... ...............................................13-17 Nm (10-13 Lb-Ft) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Radiator Center Forward Primary Crash Sensor Impact Sensor: Locations Radiator Center Forward Primary Crash Sensor Engine Compartment View The Radiator Center Forward Primary Crash Sensor is located at the lower center front of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Radiator Center Forward Primary Crash Sensor > Page 7847 Impact Sensor: Locations Right Frame Rail Primary Crash Sensor Full Body View (Part 2 Of 2) The Right Frame Rail Primary Crash Sensor is mounted on the RH side frame rail. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7848 RH Kick Panel Safing Sensor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7849 Impact Sensor: Description and Operation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH A SUPPLEMENTAL AIR BAG RESTRAINT SYSTEM HAS BEEN INVOLVED IN A CRASH WHERE THE RADIATOR SUPPORT, FRAME RAILS OR COWLS HAVE BEEN DAMAGED, INSPECT THE SENSOR MOUNTING BRACKETS FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. IN ADDITION, MAKE SURE THE BODY STRUCTURE IN THE AREA OF THE SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: Undamaged sensors will reset automatically after an accident and can be reused. The sensors are electrical switches which react to impacts according to direction and force. Sensors discriminate between impacts that require air bag inflation and impacts that do not require air bag inflation. When an impact occurs that requires air bag inflation, the sensor contacts close, completing the electrical circuit necessary for system operation. Three sensors are mounted in the vehicle. Their locations are as follows: - A primary air bag sensor at the center of the radiator support. - A primary sensor on the right frame rail. - A safing sensor at the right cowl side trim panel. At least two sensors (one primary sensor and one safing sensor) must be closed to inflate the air bag. The sensors automatically "reset" after a collision and do not need to be replaced unless they are physically damaged. Replace only if proper alignment is not possible due to bent brackets, cut wires, smashed connectors, etc. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Center Primary Crash Sensor and Bracket Impact Sensor: Service and Repair Center Primary Crash Sensor and Bracket Removal 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE POSITIVE BATTERY CABLE MUST BE DISCONNECTED PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. NOTE: To service stripped center air bag primary crash sensor and bracket retaining screws, replace screws with N808545. Tighten to 13-17 Nm (10-13 lb-ft). - When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect sensor wiring connector from wiring assembly connector. 3. Remove two screws retaining center radiator sensor. Remove sensor. Installation 1. Position sensor to radiator support. 2. Secure sensor with two retaining screws. Tighten to 10-14 Nm (7.5-10 lb-ft). 3. Connect sensor wiring connector to wiring assembly connector and secure wiring retainer. 4. Connect battery positive cable. 5. verify air bag indicator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Center Primary Crash Sensor and Bracket > Page 7852 Impact Sensor: Service and Repair Right Rear (Frame) Primary Crash Sensor and Bracket Removal 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY POSITIVE CABLE MUST BE DISCONNECTED PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. NOTE: To service stripped frame air bag sensor and bracket retaining screws, replace screws with 13 mm screw. Tighten to 13-17 Nm (10-13 lb-ft). - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect sensor wiring connector from wiring assembly connector. 3. Remove two screws retaining primary sensor to the RH frame rail. Installation 1. Position sensor to RH frame rail. 2. Secure sensor with two screws. Tighten screws to 13-17 Nm (10-13 lb-ft). 3. Connect sensor wiring connector to wiring assembly connector and secure with retainer. 4. Connect battery positive cable. 5. Verify air bag indicator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Specifications Safing Sensor: Specifications Front Air Bag Safing Sensor-to-Right Cowl Side Panel Screws .........................................................................................................8-10 Nm (71-89 Lb-In) Replacement Retaining Screws .......................................................................................................... ...............................................13-17 Nm (10-13 Lb-Ft) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Specifications > Page 7856 Safing Sensor: Locations Full Body View (Part 2 Of 2) The RH Kick Panel Safing Sensor is mounted near RH cowl panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Specifications > Page 7857 Safing Sensor: Description and Operation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH A SUPPLEMENTAL AIR BAG RESTRAINT SYSTEM HAS BEEN INVOLVED IN A CRASH WHERE THE RADIATOR SUPPORT, FRAME RAILS OR COWLS HAVE BEEN DAMAGED, INSPECT THE SENSOR MOUNTING BRACKETS FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. IN ADDITION, MAKE SURE THE BODY STRUCTURE IN THE AREA OF THE SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: Undamaged sensors will reset automatically after an accident and can be reused. The sensors are electrical switches which react to impacts according to direction and force. Sensors discriminate between impacts that require air bag inflation and impacts that do not require air bag inflation. When an impact occurs that requires air bag inflation, the sensor contacts close, completing the electrical circuit necessary for system operation. Three sensors are mounted in the vehicle. Their locations are as follows: - A primary air bag sensor at the center of the radiator support. - A primary sensor on the right frame rail. - A safing sensor at the right cowl side trim panel. At least two sensors (one primary sensor and one safing sensor) must be closed to inflate the air bag. The sensors automatically "reset" after a collision and do not need to be replaced unless they are physically damaged. Replace only if proper alignment is not possible due to bent brackets, cut wires, smashed connectors, etc. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Specifications > Page 7858 Safing Sensor: Service and Repair Removal 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY POSITIVE CABLE MUST BE DISCONNECTED FOR ONE MINUTE PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. NOTE: - To service stripped retaining screws, replace old screws with N808545. Tighten to 13-17 Nm (9-13 lb-ft). - When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Remove RH cowl side panel. 3. Disconnect sensor wiring connector from wiring assembly connector. 4. Remove two screws retaining cowl side panel. Remove sensor. Installation 1. Position sensor to cowl side panel. 2. Secure sensor with two retaining screws. Tighten to 8-10 Nm (71-89 lb-in). 3. Connect sensor wiring connector to wiring assembly connector. 4. Install RH cowl side panel. 5. Connect battery positive cable. 6. Verify air bag indicator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Standby Power Supply, Air Bag > Component Information > Service Precautions Standby Power Supply: Service Precautions WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT SERVICE IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY POSITIVE CABLE AND WAIT ONE MINUTE. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Standby Power Supply, Air Bag > Component Information > Service Precautions > Page 7862 Standby Power Supply: Description and Operation The air bag diagnostic monitor includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event the battery or battery cables are damaged in an accident before the center air bag and front air bag sensors close. The backup power supply will deplete its stored energy approximately one minute after the positive battery cable is disconnected. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation Air Bag Indicator The air bag indicator will light continuously for approximately six seconds whenever the ignition switch is turned from OFF to RUN if the air bag is working properly. If system fault is present, the indicator will either fail to light, remain lit continuously or light in a flashing manner. The flashing manner may not occur until approximately 30 seconds after the ignition switch has been turned from OFF to RUN. This is the time required for the air bag diagnostic monitor to test and verify any and all system faults. If the air bag indicator is inoperative and a system fault exists, a tone will sound signaling that the air bag indicator is inoperative and a system fault exists. Tone Generator The air bag indicator is the prime means of determining the supplemental air bag restraint system status. However, if the air bag indicator is inoperative and a system fault exists, a tone will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be serviced before further diagnosing and testing can be completed. Unless serviced, the supplemental air bag restraint system may not function properly in the event of an accident. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Full Body View (Part 2 Of 2) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7870 The Air Bag Module is located behind LH (Driver's Side) side of instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7871 Air Bag Control Module: Diagrams Air Bag Module (C209) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7872 Air Bag Module (C208) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7873 Air Bag Control Module: Description and Operation The air bag diagnostic monitor continually monitors all supplemental air bag restraint system components and wiring connections for possible faults in the system. If the air bag diagnostic monitor detects a fault in the supplemental air bag restraint system when the ignition switch is in the RUN position, a diagnostic trouble code will be displayed on the air bag indicator, located in the instrument cluster. Performing system diagnostics is the main purpose of the air bag diagnostic monitor. The air bag diagnostic monitor does not deploy the air bag in the event of a crash. The center and right rear air bag sensors are "hard wired" to the air bag, therefore, the center and right rear front primary crash sensors and RH cowl side panel air bag safing sensor determine when to deploy the air bag. FEATURES AND FUNCTIONS - The air bag diagnostic monitor illuminates the air bag indicator for approximately six seconds when the ignition switch is in the RUN position and then turns the indicator off. This shows that the air bag indicator is operational. If the air bag indicator does not illuminate or the indicator stays on or flashes at any time, a fault has been detected by the air bag diagnostic monitor. - Diagnostic trouble codes may not be displayed for approximately 30 seconds after the ignition switch is placed in the RUN position. This is the amount of time the air bag diagnostic monitor requires to perform all tests and verify system faults, if present. - Each diagnostic trouble code (a series of flashes and pauses of the air bag indicator) represents a two-digit number. Each diagnostic trouble code is always displayed at least twice. For example, a diagnostic trouble code 32 is displayed as three flashes, followed by a one-second pause, then two flashes, followed by a three-second pause. - If a system fault is present and the air bag indicator is malfunctioning, an audible tone will be heard, indicating that system service is required. The tone is a series of five sets of five beeps. This does not indicate a diagnostic trouble code 55. If the tone is heard, the air bag indicator is inoperative and a system fault that requires service is present. - If a fault exists that makes unwanted air bag deployment possible, the air bag diagnostic monitor has an internal thermal fuse that will blow (open) automatically. This removes all power to the air bag deployment circuit. CAUTION: The thermal fuse does not blow (open) because of excessive current flowing through it. DO NOT attempt to jumper out the thermal fuse with a circuit breaker or any other type of fuse. - The air bag indicator will flash the appropriate diagnostic trouble code to indicate the suspect circuit. If the indicator is malfunctioning the tone will be heard. - Diagnostic trouble codes are prioritized numerically so if two or more different faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. - The air bag diagnostic monitor includes an internal backup power supply. This feature provides sufficient backup power to deploy the air bag in the event the battery or battery cables are damaged in an accident before the center air bag and front air bag sensors close. The backup power supply will deplete its stored energy approximately one minute after the positive battery cable is disconnected. WARNING: THE BACKUP POWER SUPPLY ENERGY MUST BE DEPLETED BEFORE ANY AIR BAG COMPONENT SERVICE IS PERFORMED. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY POSITIVE CABLE AND WAIT ONE MINUTE. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7874 Air Bag Control Module: Service and Repair CAUTION: When servicing the air bag diagnostic monitor with a blown internal fuse (DTC 51), find and repair all wire damage or shorts. A blown air bag diagnostic monitor can be used to find electrical faults without replacing components unnecessarily. The diagnostic procedures are written to give safety first priority. The following steps may be taken to find the cause that initiated a blown fuse: 1. Verify the system using the old air bag diagnostic monitor and verify the wiring repairs success before proceeding. Repeat as many times as required. 2. Replace the air bag diagnostic monitor when all wire repairs are complete. 3. If the diagnostic trouble code returns after making all wiring repairs, then replace the indicated component. Removal and Installation 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY POSITIVE CABLE MUST BE DISCONNECTED FOR ONE MINUTE PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 mites or more to relearn the strategy. 2. Locate air bag diagnostic monitor beneath and to the left of the steering column and disconnect the two connectors. 3. Depress tabs retaining air bag diagnostic monitor to air bag monitor bracket. Slide air bag diagnostic monitor off air bag monitor bracket. 4. Disconnect electrical wiring connectors to air bag diagnostic monitor. Remove air bag diagnostic monitor. 5. For installation, follow removal procedures in reverse order. Prove out system. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver side air bag module connector. 5. Connect Rotunda Air Bag Simulator 105-00010 or equivalent to vehicle harness at top of steering wheel. 6. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. REACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute for backup power supply to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. Reconnect driver air bag module connector. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten nut and washer assemblies 4-6 Nm (36-53 lb-in). 4. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 5. Prove out system. Refer to System Prove Out Procedure under Testing and Inspection / Procedures / Diagnostic Strategies. WARNING: THE AIR BAG SIMULATOR(S) MUST BE REMOVED AND THE DRIVER SIDE AIR BAG MODULE RECONNECTED FOR THE SYSTEM TO BE REACTIVATED. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 7880 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Are center sensor and frame rail sensor connected and mounted to vehicle? ........................................................................................................... [ ] 2. Is right cowl side sensor connected and mounted to vehicle? ................................................................................................................................... [ ] 3. Is gray three-way connector at base of steering column connected? ........................................................................................................................ [ ] 4. Is air bag or air bag simulator connected? ...................................................................................... .......................................................................... [ ] 5. Is air bag diagnostic monitor connected? ........................................................................................ ......................................................................... [ ] 6. Is vehicle battery connected? .......................................................................................................... .......................................................................... [ ] Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation Child Seat Tether Attachment: Description and Operation TETHER ATTACHMENT Some manufacturers make safety seats with a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point behind the vehicle seat. Ford recommends the placement of tethered safety seats in a rear seating position with the tether strap attached to the tether anchoring point. The right front seating position may be used if it is the only seating position available. TETHER ANCHOR HARDWARE Tether anchor points are provided in the vehicle for child safety seats requiring a tether anchor. Tether anchor hardware kits are available from Ford Motor Company and have instructions specific to the applicable vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > General Instructions Child Seat Tether Attachment: Service and Repair General Instructions Read these instructions carefully prior to installation of the child tether strap anchor kit. Some manufacturers make child safety seats with a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point behind the vehicle seat. This vehicle has anchor points provided at the locations shown. Ford recommends placement of tethered child safety seats in a rear seating position with the tether strap attached to the tether anchoring point as shown. The front right hand seating position may be used if it is the only seating position available. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > General Instructions > Page 7887 WARNING: FAILURE TO FOLLOW THESE PRECAUTIONS COULD INCREASE THE CHANCE AND/OR SEVERITY OF INJURY IN AN ACCIDENT. LOCATING Right Front Seating Position/Second Row Bucket Seats 1. Adjust the front seat full forward for easier access to the lower rear area of the seat. 2. Locate the hole provided in the lower seat frame behind the seat cushion. Refer to illustration. 3. Refer to Installation procedures. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > General Instructions > Page 7888 Second Row 3-Passenger Bench Seat 1. Remove the second row 3-passenger bench seat. 2. Place the seat assembly upside down on a clean, protected surface. Refer to illustrations. 3. Choose the desired seating position for the child safety seat (left, center or right hand position). Locate the corresponding tether attachment hole. The holes are under the upholstery in the rear rail of the seat cushion frame. The J strip (Refer to illustration) must be detached from the rear rail to release the upholstery and gain access to any of the three (3) holes provided. 4. Refer to Installation procedures. WARNING: USE ONLY THE TETHER ATTACHMENT HOLE LOCATIONS SHOWN. THE TETHER ANCHORAGE WILL NOT PERFORM PROPERLY IF THE WRONG MOUNTING LOCATION IS USED. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > General Instructions > Page 7889 Child Seat Tether Attachment: Service and Repair Installing Child Tether Hardware INSTALLING Right Front Passenger Seating Position/Second Row Bucket Seats 1. Assemble the bolt, tether bracket and anchor to the frame rail at the rear of the seat. The tether bracket must be pointing rearward and assembled as shown. NOTE: Before installing the tether hardware, read the instructions on the package containing the thread locking material, then open the capsule and apply thread locking material to all threads on the tether attachment bolt. 2. Tighten the retaining bolt to 22-34 Nm (17-25 lb-ft). 3. Follow the child safety seat manufacturer's instructions to attach the tether strap to the tether bracket. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > General Instructions > Page 7890 Second Row 3-Passenger Bench Seat 1. Assemble the bolt, tether bracket and nut to the frame rail at the rear of the seat. The tether bracket must be pointing rearward and assembled as shown. NOTE: Before installing the tether hardware, read the instructions on the package containing the thread locking material, then open the capsule and apply thread locking material to all threads on the tether attachment bolt. 2. Tighten the retaining bolt to 22-34 Nm (17-25 lb-ft). 3. Trim the plastic J strip where required and reattach the plastic J strip to the rear rail. 4. Follow the child seat manufacturer's instructions to attach the tether strap to the tether bracket. WARNING: THE TETHER BRACKET MUST BE BOLTED DIRECTLY TO THE SHEET METAL. THE INTERIOR TRIM MUST NOT BE TRAPPED BETWEEN THE ANCHOR BRACKET AND THE SHEET METAL. FAILURE TO PROPERLY INSTALL THE ANCHOR BRACKET COULD RESULT IN IMPROPER ATTACHMENT PERFORMANCE IN THE EVENT OF AN ACCIDENT. - THE THREADED HOLE IN THE TETHER ANCHOR OR NUT HAS AN 8 MM METRIC THREAD. A WRENCH WILL BE NEEDED TO TIGHTEN THE 8MM BOLT TO THE REQUIRED TORQUE. SOME CHILD RESTRAINTS COME WITH A NON-METRIC BOLT WITH A DIFFERENT THREAD. DO NOT USE A NON-METRIC BOLT AS IT MAY BE IMPOSSIBLE TO SCREW IT ALL THE WAY INTO THE HOLE, RESULTING IN INADEQUATE RETENTION OF THE CHILD RESTRAINT. USE ONLY THE METRIC ANCHOR BOLT SUPPLIED IN THIS KIT. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications Seat Belt: Specifications Safety Belt Anchor Bolts ...................................................................................................................... .............................................30-40 Nm (22-29 Lb-Ft) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications > Page 7894 Seat Belt: Description and Operation FRONT LAP/SHOULDER SEAT BELT On bench seat installations, the inboard belts with the buckle are attached to the seat. On Econoline bucket seats and captain's chairs, the inboard buckles are attached to the floor. Attaching the tongue and buckle secures the occupant with both lower and upper restraints. CENTER LAP SEAT BELT The center seat belts do not have retractors. To lengthen the belt, tip the tongue at a right angle to the belt, and pull the tongue until the ends can be joined with front safety belt buckle end or rear safety belt and buckle over the lap. To fasten the belt, insert the tongue into the open end of the front safety belt buckle or rear safety belt and buckle until a snap is heard. To shorten the belt, pull on the loose end of the webbing. The lap belt should be snug across the hips, NEVER ACROSS THE WAIST. REAR LAP/SHOULDER SEAT BELT All of the rear outboard seats are provided with shoulder belts. Some outboard seat positions may be equipped with belts detachable from their seat anchors. Center seating positions are provided with adjustable lap belts only. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications > Page 7895 Seat Belt: Adjustments SAFETY BELTS, LAP/SHOULDER - FRONT AND REAR WARNING: THE SHOULDER BELT SHOULD BE USED ONLY ON THE SHOULDER THAT IS CLOSEST TO THAT SIDE OF THE VEHICLE. THE BELT SHOULD NEVER BE WORN UNDER THE ARM. IT SHOULD NEVER BE WORN OVER THE INSIDE SHOULDER. IF THE SHOULDER BELT IS NOT USED PROPERLY, THE CHANCES OF INJURY IN A COLLISION GREATLY INCREASE. SHOULDER PORTION ADJUSTMENT Pull the lap/shoulder belt from the retractor so that the shoulder portion of the belt crosses the shoulder and chest. Make sure the belt is not twisted. If it is, remove the twist. SAFETY BELTS, FASTENING Insert the belt tongue into the proper buckle until a snap is heard and it is felt to latch. Make sure the tongue is securely fastened to the buckle. LAP PORTION ADJUSTMENT To tighten the lap portion of the safety belt, pull up on the shoulder belt until it fits snugly. The belt should rest as low on the hips as possible. SAFETY BELTS, UNFASTENING 1. Push the release button on the buckle. This allows the tongue to unlatch from the buckle. 2. While the belt retracts, guide the tongue to its original position. If the tongue is not guided, it may strike an occupant or part of the vehicle. LAP BELTS WITHOUT RETRACTORS A lap belt without retractor is installed for the center seat of the front and rear three-passenger bench seat. This safety belt can be shortened and fastened when not in use. To use the safety belt, tip the tongue at a right angle to the belt and pull the belt over the lap until the tongue reaches the buckle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection Seat Belt: Service and Repair Cleaning and Inspection SAFETY BELT MAINTENANCE WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), IF SO EQUIPPED, CHILD SAFETY SEAT TETHER ATTACHMENTS, IF SO EQUIPPED AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS THAT ALL SAFETY BELT ASSEMBLIES IN USE DURING A COLLISION BE REPLACED UNLESS THE COLLISION WAS MINOR AND A QUALIFIED TECHNICIAN FINDS THAT THE BELTS SHOW NO DAMAGE AND CONTINUE TO OPERATE PROPERLY. SAFETY BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. Safety belt assemblies should be periodically inspected to ensure that they have not become damaged and that they remain in proper operating condition, particularly if they have been subjected to severe stress. Before installing the new safety belt assembly, safety belt retaining areas must be inspected for damage and distortion. If the retaining points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install new safety belt(s) using the appropriate instructions. Perform Functional Test Procedure. See: Testing and Inspection/Component Tests and General Diagnostics SAFETY BELT WEBBING WARNING: DO NOT BLEACH OR DYE THE WEBBING, AS WEBBING MAY WEAKEN. Clean the safety belt webbing with a mild soap solution recommended for cleaning upholstery or carpets; follow instructions provided with soap. Spot cleaning as in Method A will be sufficient when the soiled area is not excessive. In the event of severe soiling or staining, clean the entire safety bet webbing to avoid a "ring" condition. SPOT CLEANING METHOD A For stains from grease, oil, tar, water spotting, crayon, and lipstick. 1. Remove excess staining material from the fabric by scraping or wiping with a clean cloth. 2. Identify the staining material if possible. 3. Spray the stain with Ford Soil and Spot Lifter D8AZ-19526-A or equivalent from a distance of 204-254 mm (8-10 inches) as directed by instructions on can. NOTE: Using other than recommended cleaners or procedures may affect flammability or fabric appearances. CAUTION: Care should be used in application of the spot lifter to prevent it from contacting vinyl trim. 4. Allow the spot lifter to dry completely, until it forms a white powder on the surface of the fabric. 5. Brush and vacuum the white powder from the fabric. 6. If the soiled spot is not removed from the fabric, repeat Steps 1 through 5 as necessary. 7. Wipe the cleaned area with a damp cloth to remove any residual cleaner. GENERAL CLEANING METHOD B For stains such as grease, oil, tar, adhesive, crayon and lipstick. 1. Remove excess staining material from the fabric by scraping or wiping with a clean cloth. 2. Identify the staining material if possible. 3. If stain is still visible after the spot cleaning procedure (Method A), blot the soiled area with a clean cotton cloth saturated with Ford Extra Strength Spot and Stain Remover B7A-19521-AA or equivalent meeting Ford specification ESR-M5B197-A. 4. Rub in a circular motion while continuously exposing the clean portion of cloth. 5. Gradually widen the area of application onto the edges of the safety belt. 6. Repeat Steps 1 through 5 as necessary. 7. Wipe the cleaned area with a clean, damp cloth to remove any residual cleaner. GENERAL CLEANING METHOD C For stains from dirt, soil, food, soft drinks, and coffee. 1. Remove excess staining material from the fabric by scraping or wiping with a clean cloth. 2. Identify the staining material if possible. 3. Apply Rosenthal or Bissell or equivalent upholstery cleaner with cloth or brush as directed by instructions on container. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7898 4. Rub in a circular motion until the stain is removed. 5. Gradually widen the area of application to the edges of the safety belt. 6. Repeat Steps 1 through 5 as necessary. 7. Rub the cleaned area with a damp cloth to absorb residual cleaner. 8. Allow the safety belt webbing to dry at room temperature. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7899 Seat Belt: Service and Repair Removal and Installation Detachable Rear Shoulder Belt All rear outboard seating position have rear safety belt retractor and tongues. In addition to anchors in the rear floor and roof panel, some rear safety belt retractor and tongues have a detachable anchor mounted to the outboard side of the rear seat cushion frames. However, only the second row passenger side outboard seating position of a vehicle equipped with a three-passenger bench seat or captain's chair in the second row (passenger side) utilizes a rear seat shoulder strap hook above the sliding side door to stow the rear safety belt tongue when not in use. WARNING: THIS SEAT BELT GIVES NO PROTECTION UNLESS THIS END IS BUCKLED TO SIDE OF SEAT. CAUTION: Do not use seat belt for support when it is attached to stowage hook. The hook may break and you may fall. Rear Seat Safety Belt, Usage and Stowage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7900 Detachable Safety Belt Anchor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7901 Second Row RH Belt Stowage (Typical) Removal 1. Disengage the rear safety belt retractor and tongue from seat by inserting key or small screwdriver into slot located in detachable anchor. NOTE: Prior to vehicle delivery, customers must be shown the locations of the detachable anchors, their usage and the proper use of the rear seat shoulder strap hook. - Safety belt must be detached when removing rear seat. Rear seat shoulder safety belts should remain engaged in the detachable anchors, except when the rear seats require removal. WARNING: WHEN INSTALLING A REAR SEAT IN THE VEHICLE, INSTALL THE REAR SEAT IN ITS ORIGINAL LOCATION. IMPROPER INSTALLATION OF THE SEAT WILL PREVENT CORRECT USE OF THE SHOULDER SAFETY BELTS. IMPROPER USE OF THE SAFETY BELTS COULD INCREASE THE RISK AND/OR SEVERITY OF INJURY AND ACCIDENTS. 2. Lift screwdriver up and disengage belt. 3. Whenever a rear seat has been removed, the tongue end, of the detachable anchor, should be correctly stowed. Refer to illustrations provided. Installation 1. Insert detachable anchor tongue into detachable anchor until a snap is heard and the latch is felt to be engaged. - Rear safety belt retractor and tongue should not be twisted. If it is twisted, disengage tongue end and straighten twist. Reinsert tongue. Front Safety Belt Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7902 Safety Belts, Right Front Bucket/Captain's Chair, Typical View Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7903 Safety Belts, Front Outboard Position, Bucket and Captain's Chairs - Cutaway Only Removal 1. If removing the driver side safety belt buckle end, disconnect the battery ground cable. 2. If removing the driver side buckle end, disconnect the buckle end electrical connector. 3. Remove the buckle end anchor bolt. 4. Remove the safety belt buckle end from the vehicle. Installation To install, reverse the removal procedure. Seal the anchor bolt hole with Ford Caulking Cord D6AZ-19560-A. Tighten the anchor bolt to 30-40 Nm (22-29 lb-ft). Check the restraint system for proper operation. Rear Seats Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7904 Safety Belt, Rear 4-Passenger Bench Seat Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7905 Second Row Seat Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7906 Rear Captains Chairs Removal and Installation NOTE: All rear seat buckle ends are attached to rear seats and not to the floor. 1. Remove the buckle end anchor bolt from the rear seat. 2. Remove the buckle end from the vehicle. To install, reverse the removal procedure. Tighten the anchor bolt to 30-40 Nm (22-29 lb-ft). 3. Check the restraint system for proper operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7907 Seat Belt: Service and Repair Service Procedures Post Collision Inspection WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), IF SO EQUIPPED, CHILD SAFETY SEAT TETHER ATTACHMENTS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. Safety belt assemblies should be periodically inspected to make sure they have not become damaged and are in proper operating condition, particularly if subjected to severe stress. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be worked back to its original shape and structural integrity. Install the new safety belt(s) using the appropriate instructions. Perform Functional Test Procedure. See: Testing and Inspection/Component Tests and General Diagnostics Repair Notes NOTE: Safety belt buckles, center adjust tongues and belt and retractors can be replaced separately. However, if a safety belt assembly was in use during a collision, the belt and retractor must be replaced as well as the center adjust tongue and belt and buckle assembly or the center adjust tongue and the cable and buckle assembly. When replacing safety belt an buckles, safety cable and buckles, center adjust tongues and belt and retractors, use only the replacement parts specified in the Ford Master Part Catalogs for the make and model of the vehicle being serviced. Safety belt assemblies must not be interchanged between vehicle models. Safety Belt Tongue Rotated on Belt 1. Grasp the belt tongue and pull down on the closest belt webbing to form a loop through the upper (narrow and longer) slot in the tongue. 2. Working within the upper slot, rotate and fold the belt webbing over itself as required to remove the twist. 3. Pull the excess belt webbing back through the upper slot in the tongue. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7908 4. Repeat the above steps to complete the removal of the twist at the lower (wider and larger) slot in the tongue. Safety Belt Twisted at Safety Belt Guide 1. Grasp the belt webbing at shoulder belt guide ("D" Ring). NOTE: These procedures affect both wire-formed and stamped D-ring designs. 2. Rotate and fold the belt webbing over itself to remove the twist. Front Safety Belt Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7909 Safety Belts, Right Front Bucket/Captain's Chair, Typical View Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7910 Safety Belts, Front Outboard Position, Bucket and Captain's Chairs - Cutaway Only Removal and Installation 1. Remove shoulder strap guide cover. 2. Remove the upper anchor bolt attaching D-ring using Seat Belt Bolt T77L-2100-A (#50 Torx(R)) 3. Remove safety belt retractor cover safety belt retractor cover and, using the Seat Belt Bolt Bit, remove bolt attaching front safety belt retractor and tongue. 4. Remove the lower anchor bolt attaching front safety belt to front floor pan using the Seat Belt Bolt Bit. 5. Remove front door scuff plate to access bolt anchoring front safety belt. Remove bolt. 6. Remove front safety belt retractor and tongue. For installation, follow removal procedures in reverse order. - Check sealer around floor anchor bolt holes and add Ford Caulking Cord D6AZ-19560-A. - Tighten anchor bolts to 30-40 Nm (22-29 lb-ft). - Check the restraint system for proper operation. Rear Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7911 Safety Belts, Right Rear, 2nd, 3rd and 4th Row Bench Seats Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7912 Safety Belts, Right Rear, 4th and 5th Row Bench Seats Removal and Installation 1. Open the seat shoulder strap guide cover. Remove the upper anchor bolt. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7913 Detachable Safety Belt Anchor 2. If removing a rear safety belt retractor and tongue with a detachable anchor, disengage the detachable anchor tongue end from the detachable anchor on the side of the seat by inserting a key or a small screwdriver into slot in the anchor and lifting the key upward. 3. Remove bolt anchoring rear safety belt retractor and tongue to the rear floor. 4. Remove the RH or LH quarter trim panels as necessary. 5. Remove the rear seat shoulder strap opening bezel by carefully prying away from the body side panel. 6. Remove the anchor bolt securing the retractor assembly to the body side panel. 7. Remove rear safety belt retractor and tongue from vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7914 8. If the rear seat shoulder strap opening bezel is damaged, it can be removed from the rear safety belt retractor and tongue by carefully cutting through the slot located on the back side of the rear seat shoulder strap opening bezel. To prevent damage to the safety belt webbing when cutting through the slot in the rear seat shoulder strap opening bezel, place a smooth, flat, hard object such as a metal ruler between the webbing and the back side of the belt loop. 9. For installation, follow the removal procedure in reverse order. Tighten all anchor bolts to 30-40 Nm (22-29 lb-ft). Check restraint system for proper operation. Seat Belt With Anchor Plate Thread Damage 1. Remove the broken or stripped bolt and discard. 2. Drill out the internal threads in the seat belt anchor plate with a 27/64-inch drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat belt). 4. Blow out the chips. Parts Replacement Chart 5. Install the attachment parts using the proper service procedures. Refer to applicable illustration. Tighten the replacement bolt to 30-40 Nm (22-29 lb-ft). Original parts are to be replaced with the repair parts indicated in the Parts Replacement Chart. Unless specified in the guides, use original parts. 6. When repairing a multiple belt and attachment, install nut 382599-5100 to the bolt in the tunnel area from the underside of the floorpan. Tighten to 30-40 Nm (22-29 lb-ft). Seat Belt Without Anchor Plate Thread Damage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 7915 1. Remove damaged anchor reinforcement bolt and discard. Parts Replacement Chart 2. Install a new bolt with the same part number as indicated in the Parts Replacement Chart. Tighten to 30-40 Nm (22-29 lb-ft). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Page 7916 Seat Belt: Tools and Equipment Parts Replacement Chart NOTE: Bolt Torque must be maintained at 30-40 Nm (22-29 lb-ft) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation Seat Belt Buckle: Description and Operation The safety belt buckle ends are designed to lock onto the safety belt tongue and to serve as an anchor for both the lap and shoulder portions of the safety belt. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle Seat Belt Buckle: Service and Repair Rear Seat Belt Buckle Safety Belt, Rear 4-Passenger Bench Seat Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle > Page 7922 Second Row Seat Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle > Page 7923 Rear Captains Chairs Removal and Installation NOTE: All rear seat buckle ends are attached to rear seats and not to the floor. 1. Remove the buckle end anchor bolt from the rear seat. 2. Remove the buckle end from the vehicle. To install, reverse the removal procedure. Tighten the anchor bolt to 30-40 Nm (22-29 lb-ft). 3. Check the restraint system for proper operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle > Page 7924 Seat Belt Buckle: Service and Repair Removal and Installation Safety Belts, Right Front Bucket/Captain's Chair, Typical View Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle > Page 7925 Safety Belts, Front Outboard Position, Bucket and Captain's Chairs - Cutaway Only Removal 1. If removing the driver side safety belt buckle end, disconnect the battery ground cable. 2. If removing the driver side buckle end, disconnect the buckle end electrical connector. 3. Remove the buckle end anchor bolt. 4. Remove the safety belt buckle end from the vehicle. Installation To install, reverse the removal procedure. Seal the anchor bolt hole with Ford Caulking Cord D6AZ-19560-A. Tighten the anchor bolt to 30-40 Nm (22-29 lb-ft). Check the restraint system for proper operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Rear Seat Belt Buckle > Page 7926 Seat Belt Buckle: Service and Repair Service Notes NOTE: Safety belt buckles, center adjust tongues and belt and retractors can be replaced separately. However, if a safety belt assembly was in use during a collision, the belt and retractor must be replaced as well as the center adjust tongue and belt and buckle assembly or the center adjust tongue and the cable and buckle assembly. When replacing safety belt an buckles, safety cable and buckles, center adjust tongues and belt and retractors, use only the replacement parts specified in the Ford Master Part Catalogs for the make and model of the vehicle being serviced. Safety belt assemblies must not be interchanged between vehicle models. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation For some people, the safety belt may be too short even when it is fully extended. You can add about 20 cm (8 inches) to the belt length with a safety belt extension assembly. Safety belt extensions are available from your dealer. The safety belt extension assembly is only available with black webbing and standard buckle and must be of the same manufacture as the belt system to which it is attached. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation SEAT BELT WARNING SYSTEM The continuous-loop system units incorporate a safety belt warning indicator switch warning light and chime. The warning light and chime function as reminders to fasten the safety belt. If the safety belt is not buckled when the key is turned to the ON position, the light and chime will turn on for 4-8 seconds. - If the safety belt is buckled while the light is on and the chime is sounding, both light and chime will turn off. - If safety belt is buckled before the key is turned to the ON position, the light will come on for 4-8 seconds with no chime. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation SEAT BELT WARNING SYSTEM The continuous-loop system units incorporate a safety belt warning indicator switch warning light and chime. The warning light and chime function as reminders to fasten the safety belt. If the safety belt is not buckled when the key is turned to the ON position, the light and chime will turn on for 4-8 seconds. - If the safety belt is buckled while the light is on and the chime is sounding, both light and chime will turn off. - If safety belt is buckled before the key is turned to the ON position, the light will come on for 4-8 seconds with no chime. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue Seat Belt Retractor: Service and Repair Front Seat Belt, Retractor and Tongue Safety Belts, Right Front Bucket/Captain's Chair, Typical View Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7940 Safety Belts, Front Outboard Position, Bucket and Captain's Chairs - Cutaway Only Removal and Installation 1. Remove shoulder strap guide cover. 2. Remove the upper anchor bolt attaching D-ring using Seat Belt Bolt T77L-2100-A (#50 Torx(R)) 3. Remove safety belt retractor cover safety belt retractor cover and, using the Seat Belt Bolt Bit, remove bolt attaching front safety belt retractor and tongue. 4. Remove the lower anchor bolt attaching front safety belt to front floor pan using the Seat Belt Bolt Bit. 5. Remove front door scuff plate to access bolt anchoring front safety belt. Remove bolt. 6. Remove front safety belt retractor and tongue. For installation, follow removal procedures in reverse order. - Check sealer around floor anchor bolt holes and add Ford Caulking Cord D6AZ-19560-A. - Tighten anchor bolts to 30-40 Nm (22-29 lb-ft). - Check the restraint system for proper operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7941 Seat Belt Retractor: Service and Repair Rear Seat Belt, Retractor and Tongue Safety Belts, Right Rear, 2nd, 3rd and 4th Row Bench Seats Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7942 Safety Belts, Right Rear, 4th and 5th Row Bench Seats Removal and Installation 1. Open the seat shoulder strap guide cover. Remove the upper anchor bolt. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7943 Detachable Safety Belt Anchor 2. If removing a rear safety belt retractor and tongue with a detachable anchor, disengage the detachable anchor tongue end from the detachable anchor on the side of the seat by inserting a key or a small screwdriver into slot in the anchor and lifting the key upward. 3. Remove bolt anchoring rear safety belt retractor and tongue to the rear floor. 4. Remove the RH or LH quarter trim panels as necessary. 5. Remove the rear seat shoulder strap opening bezel by carefully prying away from the body side panel. 6. Remove the anchor bolt securing the retractor assembly to the body side panel. 7. Remove rear safety belt retractor and tongue from vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7944 8. If the rear seat shoulder strap opening bezel is damaged, it can be removed from the rear safety belt retractor and tongue by carefully cutting through the slot located on the back side of the rear seat shoulder strap opening bezel. To prevent damage to the safety belt webbing when cutting through the slot in the rear seat shoulder strap opening bezel, place a smooth, flat, hard object such as a metal ruler between the webbing and the back side of the belt loop. 9. For installation, follow the removal procedure in reverse order. Tighten all anchor bolts to 30-40 Nm (22-29 lb-ft). Check restraint system for proper operation. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt, Retractor and Tongue > Page 7945 Seat Belt Retractor: Service and Repair Service Notes NOTE: Safety belt buckles, center adjust tongues and belt and retractors can be replaced separately. However, if a safety belt assembly was in use during a collision, the belt and retractor must be replaced as well as the center adjust tongue and belt and buckle assembly or the center adjust tongue and the cable and buckle assembly. When replacing safety belt an buckles, safety cable and buckles, center adjust tongues and belt and retractors, use only the replacement parts specified in the Ford Master Part Catalogs for the make and model of the vehicle being serviced. Safety belt assemblies must not be interchanged between vehicle models. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Center Air Bag Primary Crash Sensor-to-Radiator Support Screws ...................................................................................................10-14 Nm (7-10 Lb-Ft) Front Air Bag Primary Crash Sensor-to-Right Frame Screws ...........................................................................................................13-17 Nm (10-13 Lb-Ft) Replacement Retaining Screws .......................................................................................................... ...............................................13-17 Nm (10-13 Lb-Ft) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Radiator Center Forward Primary Crash Sensor Impact Sensor: Locations Radiator Center Forward Primary Crash Sensor Engine Compartment View The Radiator Center Forward Primary Crash Sensor is located at the lower center front of the engine compartment. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Radiator Center Forward Primary Crash Sensor > Page 7952 Impact Sensor: Locations Right Frame Rail Primary Crash Sensor Full Body View (Part 2 Of 2) The Right Frame Rail Primary Crash Sensor is mounted on the RH side frame rail. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7953 RH Kick Panel Safing Sensor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7954 Impact Sensor: Description and Operation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH A SUPPLEMENTAL AIR BAG RESTRAINT SYSTEM HAS BEEN INVOLVED IN A CRASH WHERE THE RADIATOR SUPPORT, FRAME RAILS OR COWLS HAVE BEEN DAMAGED, INSPECT THE SENSOR MOUNTING BRACKETS FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. IN ADDITION, MAKE SURE THE BODY STRUCTURE IN THE AREA OF THE SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: Undamaged sensors will reset automatically after an accident and can be reused. The sensors are electrical switches which react to impacts according to direction and force. Sensors discriminate between impacts that require air bag inflation and impacts that do not require air bag inflation. When an impact occurs that requires air bag inflation, the sensor contacts close, completing the electrical circuit necessary for system operation. Three sensors are mounted in the vehicle. Their locations are as follows: - A primary air bag sensor at the center of the radiator support. - A primary sensor on the right frame rail. - A safing sensor at the right cowl side trim panel. At least two sensors (one primary sensor and one safing sensor) must be closed to inflate the air bag. The sensors automatically "reset" after a collision and do not need to be replaced unless they are physically damaged. Replace only if proper alignment is not possible due to bent brackets, cut wires, smashed connectors, etc. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Center Primary Crash Sensor and Bracket Impact Sensor: Service and Repair Center Primary Crash Sensor and Bracket Removal 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE POSITIVE BATTERY CABLE MUST BE DISCONNECTED PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. NOTE: To service stripped center air bag primary crash sensor and bracket retaining screws, replace screws with N808545. Tighten to 13-17 Nm (10-13 lb-ft). - When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect sensor wiring connector from wiring assembly connector. 3. Remove two screws retaining center radiator sensor. Remove sensor. Installation 1. Position sensor to radiator support. 2. Secure sensor with two retaining screws. Tighten to 10-14 Nm (7.5-10 lb-ft). 3. Connect sensor wiring connector to wiring assembly connector and secure wiring retainer. 4. Connect battery positive cable. 5. verify air bag indicator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Center Primary Crash Sensor and Bracket > Page 7957 Impact Sensor: Service and Repair Right Rear (Frame) Primary Crash Sensor and Bracket Removal 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY POSITIVE CABLE MUST BE DISCONNECTED PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. NOTE: To service stripped frame air bag sensor and bracket retaining screws, replace screws with 13 mm screw. Tighten to 13-17 Nm (10-13 lb-ft). - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Disconnect sensor wiring connector from wiring assembly connector. 3. Remove two screws retaining primary sensor to the RH frame rail. Installation 1. Position sensor to RH frame rail. 2. Secure sensor with two screws. Tighten screws to 13-17 Nm (10-13 lb-ft). 3. Connect sensor wiring connector to wiring assembly connector and secure with retainer. 4. Connect battery positive cable. 5. Verify air bag indicator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Specifications Safing Sensor: Specifications Front Air Bag Safing Sensor-to-Right Cowl Side Panel Screws .........................................................................................................8-10 Nm (71-89 Lb-In) Replacement Retaining Screws .......................................................................................................... ...............................................13-17 Nm (10-13 Lb-Ft) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Specifications > Page 7961 Safing Sensor: Locations Full Body View (Part 2 Of 2) The RH Kick Panel Safing Sensor is mounted near RH cowl panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Specifications > Page 7962 Safing Sensor: Description and Operation WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH A SUPPLEMENTAL AIR BAG RESTRAINT SYSTEM HAS BEEN INVOLVED IN A CRASH WHERE THE RADIATOR SUPPORT, FRAME RAILS OR COWLS HAVE BEEN DAMAGED, INSPECT THE SENSOR MOUNTING BRACKETS FOR DEFORMATION. IF DAMAGED, THE SENSOR SHOULD BE REPLACED WHETHER OR NOT THE AIR BAG IS DEPLOYED. IN ADDITION, MAKE SURE THE BODY STRUCTURE IN THE AREA OF THE SENSOR MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. NOTE: Undamaged sensors will reset automatically after an accident and can be reused. The sensors are electrical switches which react to impacts according to direction and force. Sensors discriminate between impacts that require air bag inflation and impacts that do not require air bag inflation. When an impact occurs that requires air bag inflation, the sensor contacts close, completing the electrical circuit necessary for system operation. Three sensors are mounted in the vehicle. Their locations are as follows: - A primary air bag sensor at the center of the radiator support. - A primary sensor on the right frame rail. - A safing sensor at the right cowl side trim panel. At least two sensors (one primary sensor and one safing sensor) must be closed to inflate the air bag. The sensors automatically "reset" after a collision and do not need to be replaced unless they are physically damaged. Replace only if proper alignment is not possible due to bent brackets, cut wires, smashed connectors, etc. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Specifications > Page 7963 Safing Sensor: Service and Repair Removal 1. Disconnect battery positive cable and wait one minute for backup power supply energy to be depleted. WARNING: THE ELECTRICAL CIRCUIT NECESSARY FOR SYSTEM DEPLOYMENT IS POWERED DIRECTLY FROM THE BATTERY AND BACKUP POWER SUPPLY. TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BATTERY POSITIVE CABLE MUST BE DISCONNECTED FOR ONE MINUTE PRIOR TO SERVICING OR REPLACING ANY SYSTEM COMPONENTS. NOTE: - To service stripped retaining screws, replace old screws with N808545. Tighten to 13-17 Nm (9-13 lb-ft). - When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Remove RH cowl side panel. 3. Disconnect sensor wiring connector from wiring assembly connector. 4. Remove two screws retaining cowl side panel. Remove sensor. Installation 1. Position sensor to cowl side panel. 2. Secure sensor with two retaining screws. Tighten to 8-10 Nm (71-89 lb-in). 3. Connect sensor wiring connector to wiring assembly connector. 4. Install RH cowl side panel. 5. Connect battery positive cable. 6. Verify air bag indicator. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Anti-Theft Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations Anti-Theft Module: Locations Full Body View (Part 2 Of 2) The Anti-Theft Module is located at the left side of the vehicle, behind "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Anti-Theft Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations > Page 7969 Anti-Theft Module: Diagrams Anti-Theft Module (C335) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Anti-Theft Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations > Page 7970 Anti-Theft Module (C336) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > Customer Interest for Anti-Theft Hood Switch: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: Customer Interest Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Anti-Theft Hood Switch: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: All Technical Service Bulletins Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations Remote Keyless Entry Module: Locations Full Body View (Part 2 Of 2) The Remote Keyless Entry Module is located behind LH "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations > Page 7988 Remote Keyless Entry Module: Diagrams Remote Keyless Entry Module (C333) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations > Page 7989 Remote Keyless Entry Module (C334) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Programming Connector > Component Information > Locations Keyless Entry Programming Connector: Locations Full Body View Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Programming Connector > Component Information > Locations > Page 7993 Location Of Keyless Entry Program Connector And Module. The Remote Keyless Entry Data Link Connector is located behind LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters Technical Service Bulletin # 95B79 Date: 950101 Campaign - Keyless Entry System Transmitters 95B79 OWNER NOTIFICATION PROGRAM Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program Dealer Letter Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Customer Notification Letter Attachment I - Admin./Labor and Parts Information FCSD Contact Talk with your FCSD Parts and Service Zone Manager about program concerns. Claims Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Labor Allowances OPERATION DESCRIPTION HOURS OPERATION Program RKE Transmitters 0.3 Hrs. B79B Parts Requirements There are no parts required for this special owner "mail-in" program. For owners returning with new transmitters and an authorization letter for a free engine oil and filter change claim for the following allowance: ^ Engine Oil and Filter Change Allowance - $25.00 ^ Enter $25.00 in MISC area of the claim as "OTHER" (Includes Labor, Parts and Markup) Claims Preparation Enter using DWE. Use code information shown below: ^ Program Code - 95B79 ^ Labor Operation - B79B See Sections 5 & 6 of the ACESII Manual for detailed instructions. Attachment II - Technical Information Remote Keyless Entry Transmitter Reprogramming NOTE: The reprogramming procedure is basically identical for all vehicles. Exceptions will be identified within each step. Remote Keyless Entry Transmitter Reprogramming 1. Locate the 2-pin RKE programming connector. Refer to RKE Programming Connector Location list below. 2. Turn ignition switch to the RUN position. 3. Using a jumper wire or alligator clip momentarily short the two terminals within the 2-pin program connector. On Econoline models you will need to short these terminals for the duration of the reprogramming procedure. The doors will lock then unlock on all models except Contour and Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 8002 Mystique. On Contour and Mystique models only the horn will sound and the exterior lights will flash. 4. Press any button on the remote keyless entry transmitter. All doors will lock then unlock to verify transmitter has been programmed. The horn will sound and the exterior lights will flash on the Contour and Mystique. NOTE: Programming in the first transmitter will erase all other previously programmed transmitters. All transmitters that are to operate with the vehicle (up to four transmitters) must be programmed during Steps 4 and 5. 5. Repeat Step 4 for any additional remote transmitters to be reprogrammed. 6. Turn ignition switch OFF. All doors should lock then unlock. On Contour and Mystique models the horn will sound and the exterior lights will flash. 7. Remove short (Econoline models only). 8. Install any trim previously removed. 9. Verify transmitter operation. RKE Programming Connector Location The Two-Pin RKE Programming Connector Is Located; Taurus/Sable Wagons - behind the left side trim panel inside the cargo area. Remove the trim panel for access to the connector. Taurus/Sable Sedans - Under the left side of the package tray. Contour/Mystique - under the right side of the instrument panel, behind right side of glove compartment. Reach up behind the glove compartment for access to the connector. Probe - in the trunk behind the subwoofer on the right side of the vehicle. Remove the subwoofer (if so equipped) for access to the connector. Mark VIII, Crown Victoria, Grand Marquis and Town Car - behind the glove compartment. Open the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. F-Series and Bronco - under the drivers side of the instrument panel above the drivers right foot area. Mustang - in the trunk behind the left side trim panel. Loosen the lining board (convertibles only) and the rear and left side trim covers to gain access to the connector. Thunderbird/Cougar - behind the left side trim panel inside the trunk. Remove the trim panel for access to the connector. Explorer - behind the left quarter utility compartment access panel. Remove the panel for access to the connector. Windstar - behind and to the right of the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. Econoline - under the instrument panel to the left of the steering column. Continental - under the right side of the instrument panel near the glove compartment. Remove the panel from beneath the instrument panel for access to the connector. For further information regarding connector location and color-coding refer to the appropriate Electrical Vacuum and Troubleshooting Manual (EVTM). Dealer Letter To: All Ford and Lincoln-Mercury Dealers Subject: Owner Notification Program 95B79 - Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program OASIS NO Owner List NO Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 8003 Parts Return NO Program Terms Available through October 31, 1996 Affected Vehicles 1994-model Continental, Explorer, Crown Victoria, Grand Marquis and Town Car, 1994 and 1995-model Mustang, Taurus, Sable, Thunderbird, Cougar, Mark VIII, Probe, F-Series, Bronco, Econoline and 1995-model Contour, Mystique and Windstar vehicles equipped with the factory installed remote keyless entry system option. (This is the rectangular-shaped transmitter, manufactured by TRW Corp.) Reason For This Program The remote keyless entry system transmitter positive battery terminal contact surface may develop corrosion and result in intermittent transmitter operation and/or unnecessary battery replacement. Service Action Owners of affected vehicles will be notified of a special "mail-in" up-grade program and will be instructed to return their transmitters in a special prepaid mailing envelope. The transmitters will be serviced at a central facility and returned to owners. This bulletin provides instructions if owners should return to dealers for service. Owners will use the special mailing envelope for this special "mail-in" service. However, there are two situations where an owner may contact their dealer: 1.) where the special mailing envelope cannot be located, or 2.) where the central servicing facility was unable to perform the required upgrade of the transmitter for technical reasons. Dealers are required to provide transmitter reprogramming service along with a free engine oil and filter change. In these situations customers will have received an authorization letter along with the new transmitters. Additionally, customers are informed that the authorization letter and the transmitters are to be presented when requesting this service. Limited-Time Program This special "mail-in" program will only be available through October 31, 1996. Special Toll-Free Number for Owner's Questions A special toll-free number is available for owners (1-800-490-4288) from 7:30 a.m. to 7:30 p.m. weekdays and 8:00 a.m. to 3:00 p.m. on Saturdays (All times are Eastern Time). Technical/Administrative Questions? Claims Information 1-800-423-8851 Other Program Questions 1-800-325-5621 Attachments Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Owner Letter Serial Number: xxxxxxxxxxxxxxxxx 95B79 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a special no-charge Service Program 95B79 to owners of certain 1994 and 1995-model vehicles equipped with the Ford Remote Keyless Entry System. Reason For This Program: Battery contact corrosion inside the small rectangular shaped Ford Remote Keyless Entry System transmitters (with your vehicle's keys) may cause the system to operate intermittently and possibly result in unnecessary battery replacement. No Charge Service With Drop-In-The-Mailbox Convenience: At no charge to you, Ford Motor Company will upgrade your remote transmitters for Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 8004 proper trouble-free operation via a special mail-in service program. This special mail-in program is designed to provide you with a quick, convenient way to upgrade your remote transmitters and is available to you through October 31, 1996. (If you desire, you could have this service performed by your Ford or Lincoln-Mercury dealer.) Return Transmitters In Special Prepaid Mailer: Use the enclosed prepaid mailing envelope to return all of your remote transmitters for the vehicle identified by the serial number above. Just drop the envelope (with the transmitters enclosed) in the mail. For your security and protection, the prepaid mailer does not require your name or address. The bar-coding on the label will enable us to identify you. Return Only The Transmitters: Please return the remote transmitters only. Detach them from the large key ring. (During the time that your transmitters are being upgraded, remember that you will have to use your key; we apologize for this inconvenience.) Processing Time: Counting mail time to and from our service center, we expect your transmitters will be returned to you within 10 working days. If you have not received your transmitters back by this time, please call the following toll-free number: 1-800-490-4288. Changed Address? Please fill-out the enclosed postcard with your new address and return it in the prepaid mailer with your transmitters. Sold Your Vehicle? Do nothing and discard this communication. Questions? A special toll-free number (1-800-490-4288) is available if you have questions on this program. Ford representatives are available weekdays from 7:30 a.m. to 7:30 p.m. and on Saturdays from 8:00 a.m. to 3:00 p.m. Eastern time. Have your vehicle serial number ready when you call. It is printed above. We are taking this action as part of our on-going efforts to maintain owner confidence in our products. We hope this special mail-in program will confirm your continued satisfaction with your Ford Remote Keyless Entry System. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters Technical Service Bulletin # 95B79 Date: 950101 Campaign - Keyless Entry System Transmitters 95B79 OWNER NOTIFICATION PROGRAM Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program Dealer Letter Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Customer Notification Letter Attachment I - Admin./Labor and Parts Information FCSD Contact Talk with your FCSD Parts and Service Zone Manager about program concerns. Claims Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Labor Allowances OPERATION DESCRIPTION HOURS OPERATION Program RKE Transmitters 0.3 Hrs. B79B Parts Requirements There are no parts required for this special owner "mail-in" program. For owners returning with new transmitters and an authorization letter for a free engine oil and filter change claim for the following allowance: ^ Engine Oil and Filter Change Allowance - $25.00 ^ Enter $25.00 in MISC area of the claim as "OTHER" (Includes Labor, Parts and Markup) Claims Preparation Enter using DWE. Use code information shown below: ^ Program Code - 95B79 ^ Labor Operation - B79B See Sections 5 & 6 of the ACESII Manual for detailed instructions. Attachment II - Technical Information Remote Keyless Entry Transmitter Reprogramming NOTE: The reprogramming procedure is basically identical for all vehicles. Exceptions will be identified within each step. Remote Keyless Entry Transmitter Reprogramming 1. Locate the 2-pin RKE programming connector. Refer to RKE Programming Connector Location list below. 2. Turn ignition switch to the RUN position. 3. Using a jumper wire or alligator clip momentarily short the two terminals within the 2-pin program connector. On Econoline models you will need to short these terminals for the duration of the reprogramming procedure. The doors will lock then unlock on all models except Contour and Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 8010 Mystique. On Contour and Mystique models only the horn will sound and the exterior lights will flash. 4. Press any button on the remote keyless entry transmitter. All doors will lock then unlock to verify transmitter has been programmed. The horn will sound and the exterior lights will flash on the Contour and Mystique. NOTE: Programming in the first transmitter will erase all other previously programmed transmitters. All transmitters that are to operate with the vehicle (up to four transmitters) must be programmed during Steps 4 and 5. 5. Repeat Step 4 for any additional remote transmitters to be reprogrammed. 6. Turn ignition switch OFF. All doors should lock then unlock. On Contour and Mystique models the horn will sound and the exterior lights will flash. 7. Remove short (Econoline models only). 8. Install any trim previously removed. 9. Verify transmitter operation. RKE Programming Connector Location The Two-Pin RKE Programming Connector Is Located; Taurus/Sable Wagons - behind the left side trim panel inside the cargo area. Remove the trim panel for access to the connector. Taurus/Sable Sedans - Under the left side of the package tray. Contour/Mystique - under the right side of the instrument panel, behind right side of glove compartment. Reach up behind the glove compartment for access to the connector. Probe - in the trunk behind the subwoofer on the right side of the vehicle. Remove the subwoofer (if so equipped) for access to the connector. Mark VIII, Crown Victoria, Grand Marquis and Town Car - behind the glove compartment. Open the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. F-Series and Bronco - under the drivers side of the instrument panel above the drivers right foot area. Mustang - in the trunk behind the left side trim panel. Loosen the lining board (convertibles only) and the rear and left side trim covers to gain access to the connector. Thunderbird/Cougar - behind the left side trim panel inside the trunk. Remove the trim panel for access to the connector. Explorer - behind the left quarter utility compartment access panel. Remove the panel for access to the connector. Windstar - behind and to the right of the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. Econoline - under the instrument panel to the left of the steering column. Continental - under the right side of the instrument panel near the glove compartment. Remove the panel from beneath the instrument panel for access to the connector. For further information regarding connector location and color-coding refer to the appropriate Electrical Vacuum and Troubleshooting Manual (EVTM). Dealer Letter To: All Ford and Lincoln-Mercury Dealers Subject: Owner Notification Program 95B79 - Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program OASIS NO Owner List NO Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 8011 Parts Return NO Program Terms Available through October 31, 1996 Affected Vehicles 1994-model Continental, Explorer, Crown Victoria, Grand Marquis and Town Car, 1994 and 1995-model Mustang, Taurus, Sable, Thunderbird, Cougar, Mark VIII, Probe, F-Series, Bronco, Econoline and 1995-model Contour, Mystique and Windstar vehicles equipped with the factory installed remote keyless entry system option. (This is the rectangular-shaped transmitter, manufactured by TRW Corp.) Reason For This Program The remote keyless entry system transmitter positive battery terminal contact surface may develop corrosion and result in intermittent transmitter operation and/or unnecessary battery replacement. Service Action Owners of affected vehicles will be notified of a special "mail-in" up-grade program and will be instructed to return their transmitters in a special prepaid mailing envelope. The transmitters will be serviced at a central facility and returned to owners. This bulletin provides instructions if owners should return to dealers for service. Owners will use the special mailing envelope for this special "mail-in" service. However, there are two situations where an owner may contact their dealer: 1.) where the special mailing envelope cannot be located, or 2.) where the central servicing facility was unable to perform the required upgrade of the transmitter for technical reasons. Dealers are required to provide transmitter reprogramming service along with a free engine oil and filter change. In these situations customers will have received an authorization letter along with the new transmitters. Additionally, customers are informed that the authorization letter and the transmitters are to be presented when requesting this service. Limited-Time Program This special "mail-in" program will only be available through October 31, 1996. Special Toll-Free Number for Owner's Questions A special toll-free number is available for owners (1-800-490-4288) from 7:30 a.m. to 7:30 p.m. weekdays and 8:00 a.m. to 3:00 p.m. on Saturdays (All times are Eastern Time). Technical/Administrative Questions? Claims Information 1-800-423-8851 Other Program Questions 1-800-325-5621 Attachments Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Owner Letter Serial Number: xxxxxxxxxxxxxxxxx 95B79 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a special no-charge Service Program 95B79 to owners of certain 1994 and 1995-model vehicles equipped with the Ford Remote Keyless Entry System. Reason For This Program: Battery contact corrosion inside the small rectangular shaped Ford Remote Keyless Entry System transmitters (with your vehicle's keys) may cause the system to operate intermittently and possibly result in unnecessary battery replacement. No Charge Service With Drop-In-The-Mailbox Convenience: At no charge to you, Ford Motor Company will upgrade your remote transmitters for Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 8012 proper trouble-free operation via a special mail-in service program. This special mail-in program is designed to provide you with a quick, convenient way to upgrade your remote transmitters and is available to you through October 31, 1996. (If you desire, you could have this service performed by your Ford or Lincoln-Mercury dealer.) Return Transmitters In Special Prepaid Mailer: Use the enclosed prepaid mailing envelope to return all of your remote transmitters for the vehicle identified by the serial number above. Just drop the envelope (with the transmitters enclosed) in the mail. For your security and protection, the prepaid mailer does not require your name or address. The bar-coding on the label will enable us to identify you. Return Only The Transmitters: Please return the remote transmitters only. Detach them from the large key ring. (During the time that your transmitters are being upgraded, remember that you will have to use your key; we apologize for this inconvenience.) Processing Time: Counting mail time to and from our service center, we expect your transmitters will be returned to you within 10 working days. If you have not received your transmitters back by this time, please call the following toll-free number: 1-800-490-4288. Changed Address? Please fill-out the enclosed postcard with your new address and return it in the prepaid mailer with your transmitters. Sold Your Vehicle? Do nothing and discard this communication. Questions? A special toll-free number (1-800-490-4288) is available if you have questions on this program. Ford representatives are available weekdays from 7:30 a.m. to 7:30 p.m. and on Saturdays from 8:00 a.m. to 3:00 p.m. Eastern time. Have your vehicle serial number ready when you call. It is printed above. We are taking this action as part of our on-going efforts to maintain owner confidence in our products. We hope this special mail-in program will confirm your continued satisfaction with your Ford Remote Keyless Entry System. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 8013 Keyless Entry Transmitter: Service and Repair To program (or reprogram) transmitter(s) into the electronic door lock control, perform the following steps: 1. Turn the ignition switch to the ON or ON/ACC position and momentarily short the two terminals of the program connector (C2), a two-pin connector located below the driver's side of the instrument panel at the base of the steering column. All doors should lock and then unlock. 2. Press any button on each transmitter. All doors should lock and then unlock. If the door locks do not respond, press the button again (up to three times maximum with the same transmitter). If the door locks still fail to respond, go to Pinpoint Test D. 3. Repeat Step 2 to program additional transmitters into the control module (up to four transmitters maximum). 4. Turn ignition switch off. All doors should lock and then unlock. 5. Make sure the short has been removed from the program connector C2. 6. Verify that the transmitters have been successfully programmed by pressing the LOCK or UNLOCK button on each transmitter, and observing that the system responds by locking and/or unlocking the doors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Anti-Theft Indicator <--> [Security Lamp/Indicator] > Component Information > Diagrams Anti-Theft Indicator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Except Premium Sound Amplifier (C213) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Except Premium Sound > Page 8022 Amplifier: Diagrams Premium Sound Amplifier (With Premium Sound) (C243) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Except Premium Sound > Page 8023 Amplifier (C213) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8033 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8034 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8035 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8036 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8037 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8038 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8039 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8045 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8046 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8047 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8048 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8049 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8050 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8051 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Radio Control <--> [Remote Control, Audio - Stereo] > Component Information > Diagrams Remote Radio Control Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8063 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8064 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8065 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8066 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8067 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8068 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8069 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8075 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8076 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8077 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8078 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8079 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8080 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8081 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Anti-Theft Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations Anti-Theft Module: Locations Full Body View (Part 2 Of 2) The Anti-Theft Module is located at the left side of the vehicle, behind "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Anti-Theft Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations > Page 8086 Anti-Theft Module: Diagrams Anti-Theft Module (C335) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Anti-Theft Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations > Page 8087 Anti-Theft Module (C336) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations Remote Keyless Entry Module: Locations Full Body View (Part 2 Of 2) The Remote Keyless Entry Module is located behind LH "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations > Page 8091 Remote Keyless Entry Module: Diagrams Remote Keyless Entry Module (C333) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations > Page 8092 Remote Keyless Entry Module (C334) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > Customer Interest for Anti-Theft Hood Switch: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: Customer Interest Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Anti-Theft Hood Switch: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: All Technical Service Bulletins Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Behind RVs Guidelines Towing Information: Technical Service Bulletins Vehicle - Towing Behind RVs Guidelines Article No. 98-5A-12 03/18/98 ^ BRAKES - WEIGHT LIMITATIONS FOR TOWING ^ RECREATIONAL VEHICLES - WEIGHT RATINGS FOR UNBRAKED TOWING LESS THAN GROSS COMBINATION WEIGHT RATING (GCWR) ^ TOWING BEHIND RECREATIONAL VEHICLES - RECOMMENDED GUIDELINES ^ TRANSAXLE/TRANSMISSION/TRANSFER CASE - VEHICLES TOWED BEHIND RECREATIONAL VEHICLES - RECOMMENDED TOWING GUIDELINES FORD: 1988-93 FESTIVA 1988-94 TEMPO 1989-96 PROBE, TAURUS SHO 1991-97 ESCORT 1994-96 ASPIRE LINCOLN-MERCURY: 1988-94 TOPAZ 1991-94 CAPRI 1991-97 TRACER LIGHT TRUCK: 1988-96 AEROSTAR, BRONCO, E-350, F SUPER DUTY, F-250, F-350, F-53 MOTORHOME, RANGER 1988-97 F-150 1991-96 EXPLORER 1997 MOUNTAINEER ISSUE: Many motorhome owners tow a vehicle when traveling. Improper techniques can "overload" the brake system of the tow vehicle or damage the drivetrain of the vehicle being towed. ACTION: Use the information and charts shown in this TSB article to properly match tow vehicle, towed vehicle and towing method. TOWING METHODS 1. TRAILER - The vehicle is loaded onto and secured to a trailer and simply acts as "secured" cargo. 2. DOLLY - The vehicle is "partially" loaded and partially towed. Either front or rear wheels are loaded and secured to a "towing dolly" and the other wheels roll on the road. 3. TOW BAR - All of the vehicle wheels roll on the pavement. The towed vehicle's steering column must be unlocked so that it can track correctly behind the tow vehicle. WEIGHT RATINGS AND BRAKES ^ GVWR (Gross Vehicle Weight Rating) - is the MAXIMUM allowable weight of the towing vehicle, passengers and cargo ^ GCWR (Gross Combined Weight Rating) - is the MAXIMUM allowable weight of the towing vehicle and the weight of the trailer or vehicle being towed, including all passengers and cargo ^ BRAKES - The motorhome brakes are designed and rated for the GVWR of that vehicle and will provide adequate braking for trailers and towing vehicles up to 680 kg (1500 lb) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Behind RVs Guidelines > Page 8112 CAUTION: SEPARATE AUXILIARY BRAKES ARE REQUIRED ON TRAILERS OR TOWED VEHICLES OVER 680 KG (1500 LBS). DO NOT CONNECT A TRAILER'S, DOLLY'S OR OTHER TOWED VEHICLE'S BRAKE SYSTEM TO THE TOWING VEHICLE'S BRAKE SYSTEM. TOWED VEHICLES 1. Trailer-towed - The vehicle should be loaded on the trailer in a manner to: a. achieve a trailer tongue load of 10-15% of total trailer weight, b. not exceed the trailer or hitch ratings and c. be securely tied down. 2. Dolly-towed - For front wheel drive vehicles, towing an automatic transaxle (ATX)-equipped vehicle behind another vehicle, such as a Recreational Vehicle (RV), requires that a front wheel dolly or trailer be used. NOTE: TEMPO ALL-WHEEL DRIVE MODELS MUST BE TRAILER-TOWED. DO NOT TOW THESE VEHICLES USING A TWO-WHEEL TOWING DOLLY. CAUTION: DO NOT TOW A VEHICLE WITH AN AUTOMATIC (ATX) TRANSAXLE WITH THE DRIVE WHEELS ON THE GROUND. DAMAGE TO THE TRANSAXLE MAY RESULT. 3. Tow Bar-towed - Vehicles which can be successfully towed with a tow bar are listed in the following chart. Additional vehicle-specific information follows the chart. ALL VEHICLES NOTE: DO NOT TOW ANY VEHICLE AT A SPEED FASTER THAN 88 KM/H (55 MPH). THE MAXIMUM TOWING DISTANCE (WHEN TOWED CORRECTLY) IS UNLIMITED. WARNING: NEVER USE A TOW BAR THAT ATTACHES ONLY TO THE BUMPER. MTX-EQUIPPED VEHICLES Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Behind RVs Guidelines > Page 8113 Towing a manual transaxle (MTX)-equipped vehicle with the drive wheels on the ground is acceptable only if the vehicle is towed in a forward direction. The parking brake must be released and the gear shift lever must be in Neutral. ^ For Aspire, Festiva, Escort and Tracer, the ignition key must be in the ACO position, the battery must be disconnected to eliminate battery drain, and the steering wheel must be unlocked ^ For Capri, the ignition key must be in the OFF position and the steering wheel unlocked ^ Refer to the specific vehicle Owner Guide for complete details CAUTION: TOWING MTX-EQUIPPED VEHICLES INCORRECTLY MAY RESULT IN TRANSAXLE DAMAGE. TRUCKS ^ The steering wheel must be unlocked by placing the ignition key in the OFF position ^ Manual transmission shift lever must be in Neutral ^ On 4X4 manual shift transfer cases, the shift lever must be in Neutral ^ 4X4 locking hubs (both manual and automatic) must be unlocked ^ Refer to the specific vehicle Owner Guide for complete details OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-24-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Locations > Electronic Brake Connector Trailer/Camper Adapter: Locations Electronic Brake Connector Full Body View (Part 2 Of 2) The Electronic Brake Connector is located at the LH side of the instrument panel, near air bag module. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Locations > Electronic Brake Connector > Page 8118 Trailer/Camper Adapter: Locations Trailer/Camper Adapter Connector Class I Full Body View (Part 2 Of 2) The Trailer/Camper Adapter Connector is located below LH side of the rear bumper. Class II Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Locations > Electronic Brake Connector > Page 8119 Full Body View (Part 2 Of 2) The Trailer/Camper Adapter Connector is located below LH side of the rear bumper. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions Trailer/Camper Adapter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8122 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8123 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8124 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8125 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8126 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8127 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8128 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8129 Trailer/Camper Adapter: Connector Views Electronic Brake Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8130 Trailer Adapter (Class II Only) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8131 Trailer/Camper Adapter: Electrical Diagrams Trailer/Camper Adapter (Class I) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8132 Trailer/Camper Adapter (Class II) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8133 Trailer/Camper Adapter (Class II) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8134 Trailer/Camper Adapter (Class II) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8135 Trailer/Camper Adapter (Class II) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8136 Trailer/Camper Adapter (Class II) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8137 Trailer/Camper Adapter (Class II) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8138 Trailer/Camper Adapter (Electronic Brake) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay Trailer Backup Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 8143 Trailer Battery Charge Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 8144 Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Locations > Electronic Brake Connector Trailer/Camper Adapter: Locations Electronic Brake Connector Full Body View (Part 2 Of 2) The Electronic Brake Connector is located at the LH side of the instrument panel, near air bag module. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Locations > Electronic Brake Connector > Page 8149 Trailer/Camper Adapter: Locations Trailer/Camper Adapter Connector Class I Full Body View (Part 2 Of 2) The Trailer/Camper Adapter Connector is located below LH side of the rear bumper. Class II Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Locations > Electronic Brake Connector > Page 8150 Full Body View (Part 2 Of 2) The Trailer/Camper Adapter Connector is located below LH side of the rear bumper. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions Trailer/Camper Adapter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8153 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8154 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8155 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8156 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8157 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8158 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8159 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8160 Trailer/Camper Adapter: Connector Views Electronic Brake Modified Vehicle Power Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8161 Trailer Adapter (Class II Only) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8162 Trailer/Camper Adapter: Electrical Diagrams Trailer/Camper Adapter (Class I) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8163 Trailer/Camper Adapter (Class II) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8164 Trailer/Camper Adapter (Class II) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8165 Trailer/Camper Adapter (Class II) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8166 Trailer/Camper Adapter (Class II) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8167 Trailer/Camper Adapter (Class II) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8168 Trailer/Camper Adapter (Class II) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer/Camper Adapter <--> [Trailer Connector] > Component Information > Diagrams > Diagram Information and Instructions > Page 8169 Trailer/Camper Adapter (Electronic Brake) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service Bulletins > Running Boards - Noise/Vibration Installation Tips Auxiliary Step / Running Board: Technical Service Bulletins Running Boards - Noise/Vibration Installation Tips Article No. 95-8-6 04/24/95 ^ RUNNING BOARDS - INCORRECTLY INSTALLED - NVH CONCERNS ^ NOISE - VIBRATION - RUNNING BOARDS - INCORRECTLY INSTALLED LIGHT TRUCK: 1987-90 BRONCO II 1987-95 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-95 F SUPER DUTY 1991-95 EXPLORER This TSB is being republished in its entirety to include vehicles through the 1995 model year. ISSUE: Running boards which are incorrectly installed may result in noise/vibration complaints. ACTION: Install running boards to either the body or frame; NEVER to both unless the mounting system uses isolated mounts. A manufacturer's instruction to attach running boards to both body and frame should be immediately questioned because such action provides a direct path from chassis to body for road vibration and noise. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-4-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 702000, 703000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Front Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 8182 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 8183 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Rear Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 8189 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 8190 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > Customer Interest for Anti-Theft Hood Switch: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: Customer Interest Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Anti-Theft Hood Switch: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: All Technical Service Bulletins Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement Part Article No. 01-19-4 10/01/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES 1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 201000, 201200 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Frame Rivet Replacement with Bolts Service Tip > Page 8214 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Description and Operation Ash Tray: Description and Operation The cigar lighter element has a low resistance heating coil which operates much like the coil used in a portable heater. When the element is pushed completely in, the circuit is closed and current flows through the heating coil to the ground. When sufficient heat is generated, the element will overcome the spring pressure of the bimetal retaining fingers and be released. Instrument panel ash receptacles and cigar lighter knob and elements are located in the center of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Ash Receptacle Ash Tray: Service and Repair Ash Receptacle Removal and Installation To remove the instrument panel ash receptacle, pull it out to the stop, reach under the drawer and push the release tab at the back center. To install, slide the drawer into the retainer to the full closed position. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Ash Receptacle > Page 8221 Ash Tray: Service and Repair Ash Receptacle and Retainer Removal and Installation 1. Remove the engine cover. 2. Open instrument panel ash receptacle and remove two screws attaching front of instrument panel ash receptacle drawer retainer to the instrument panel. 3. Unsnap and remove the center moulding. 4. Remove the screw that attaches the rear of the instrument panel ash receptacle drawer retainer to instrument panel. 5. Remove instrument panel ash receptacle from instrument panel. 6. For installation, follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation Console: Description and Operation The floor console is a part of the engine cover and consists of: Coin holder - Tissue storage - Dual cup holder - CD/cassette storage Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation > Page 8225 Console: Service and Repair Removal 1. Open console door to the full open position. 2. Reach into compartment, pull release latch while lifting the console. Installation 1. Locate console tabs into tracks on engine cover and push down until console latch engages engine cover hook. 2. Close console door. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver side air bag module connector. 5. Connect Rotunda Air Bag Simulator 105-00010 or equivalent to vehicle harness at top of steering wheel. 6. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. REACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute for backup power supply to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. Reconnect driver air bag module connector. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten nut and washer assemblies 4-6 Nm (36-53 lb-in). 4. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 5. Prove out system. Refer to System Prove Out Procedure under Testing and Inspection / Procedures / Diagnostic Strategies. WARNING: THE AIR BAG SIMULATOR(S) MUST BE REMOVED AND THE DRIVER SIDE AIR BAG MODULE RECONNECTED FOR THE SYSTEM TO BE REACTIVATED. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8231 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Are center sensor and frame rail sensor connected and mounted to vehicle? ........................................................................................................... [ ] 2. Is right cowl side sensor connected and mounted to vehicle? ................................................................................................................................... [ ] 3. Is gray three-way connector at base of steering column connected? ........................................................................................................................ [ ] 4. Is air bag or air bag simulator connected? ...................................................................................... .......................................................................... [ ] 5. Is air bag diagnostic monitor connected? ........................................................................................ ......................................................................... [ ] 6. Is vehicle battery connected? .......................................................................................................... .......................................................................... [ ] Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > Customer Interest: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door Door Locks: Customer Interest Door Lock Cylinder - Loose in Replacement Door Article No. 95-24-4 12/04/95 ^ DOOR - REPLACEMENT DOOR HAS LOOSE FITTING DOOR LOCK CYLINDER - SERVICE TIP ^ LOCK - LOOSE FITTING DOOR LOCK CYLINDER - SERVICE TIP LIGHT TRUCK: 1981-96 F-150-350 SERIES 1983-96 BRONCO, RANGER 1986-95 AEROSTAR 1988-96 F SUPER DUTY 1992-96 ECONOLINE 1995-96 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-96 F & B SERIES ISSUE: New replacement doors for past model years have a larger lock cylinder hole diameter. A loose fit will occur when installing the door lock cylinder. The lock cylinder mounting hole diameter in new doors has been increased in preparation for a new style lock cylinder. New locks will be phased in for future production. ACTION: Install a spacer for the larger diameter door lock cylinder mounting hole. Refer to the following Service Procedure for details. NOTE: THE DOOR LOCK CYLINDER SPACER HAS BEEN ADDED TO CERTAIN 1996 MODEL YEAR VEHICLES TO ELIMINATE THE LOOSE FIT CONDITION FROM THE SMALLER DOOR LOCK CYLINDER. SOME VEHICLES MAY BE BUILT WITH SPACERS ON ONE SIDE ONLY. THIS IS DUE TO THE BALANCE OF SUPPLIES OF RIGHT AND LEFT DOORS AT THE ASSEMBLY PLANTS AT THE TIME OF MODEL YEAR CHANGEOVER. SERVICE PROCEDURE DOOR LOCK CYLINDER INSTALLATION/REMOVAL 1. Whenever the door lock cylinder is removed, check for presence of lock cylinder spacer in the door in the lock hole. If one is present, check for damage and replace if necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > Customer Interest: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door > Page 8241 2. If replacement is necessary, refer to the Lock Spacer Usage Chart (Figure 1) for proper part number application. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > Customer Interest: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door > Page 8242 3. Snap a new spacer into the hole from outside the door (Figure 2). DOOR OR LIFTGATE INSTALLATION/REMOVAL When replacing the door of liftgate assembly, the new door or liftgate may have the larger lock cylinder hole. Measure the hole diameter (Figure 2). If dimension "X" is more than 24 mm, then a spacer is required. If it is less than 24 mm, then a spacer cannot be used. NOTE: EVEN IF THE ORIGINAL DOOR HAS A SPACER, ONE IS NOT NEEDED IF THE "X" DIMENSION IS LESS THAN 24 mm IN THE NEW DOOR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > Customer Interest: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door > Page 8243 GENERAL INFORMATION REGARDING SPACER USAGE The purpose of the spacer is to allow the flexibility of phasing in future lock designs without having to coordinate doors and locks in production or having to maintain two unique service doors. In general, the spacers are to be used with new doors (large hole) and old locks. The new doors are being phased in ahead of the new locks. PART NUMBER PART NAME F6TZ-1521890-AA Door Lock cylinder Spacer F6UZ-1521890-AA Door Lock Cylinder Spacer F68Z-1621890-AA Door Lock Cylinder Spacer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 111000, 112000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door Door Locks: All Technical Service Bulletins Door Lock Cylinder - Loose in Replacement Door Article No. 95-24-4 12/04/95 ^ DOOR - REPLACEMENT DOOR HAS LOOSE FITTING DOOR LOCK CYLINDER - SERVICE TIP ^ LOCK - LOOSE FITTING DOOR LOCK CYLINDER - SERVICE TIP LIGHT TRUCK: 1981-96 F-150-350 SERIES 1983-96 BRONCO, RANGER 1986-95 AEROSTAR 1988-96 F SUPER DUTY 1992-96 ECONOLINE 1995-96 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-96 F & B SERIES ISSUE: New replacement doors for past model years have a larger lock cylinder hole diameter. A loose fit will occur when installing the door lock cylinder. The lock cylinder mounting hole diameter in new doors has been increased in preparation for a new style lock cylinder. New locks will be phased in for future production. ACTION: Install a spacer for the larger diameter door lock cylinder mounting hole. Refer to the following Service Procedure for details. NOTE: THE DOOR LOCK CYLINDER SPACER HAS BEEN ADDED TO CERTAIN 1996 MODEL YEAR VEHICLES TO ELIMINATE THE LOOSE FIT CONDITION FROM THE SMALLER DOOR LOCK CYLINDER. SOME VEHICLES MAY BE BUILT WITH SPACERS ON ONE SIDE ONLY. THIS IS DUE TO THE BALANCE OF SUPPLIES OF RIGHT AND LEFT DOORS AT THE ASSEMBLY PLANTS AT THE TIME OF MODEL YEAR CHANGEOVER. SERVICE PROCEDURE DOOR LOCK CYLINDER INSTALLATION/REMOVAL 1. Whenever the door lock cylinder is removed, check for presence of lock cylinder spacer in the door in the lock hole. If one is present, check for damage and replace if necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door > Page 8249 2. If replacement is necessary, refer to the Lock Spacer Usage Chart (Figure 1) for proper part number application. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door > Page 8250 3. Snap a new spacer into the hole from outside the door (Figure 2). DOOR OR LIFTGATE INSTALLATION/REMOVAL When replacing the door of liftgate assembly, the new door or liftgate may have the larger lock cylinder hole. Measure the hole diameter (Figure 2). If dimension "X" is more than 24 mm, then a spacer is required. If it is less than 24 mm, then a spacer cannot be used. NOTE: EVEN IF THE ORIGINAL DOOR HAS A SPACER, ONE IS NOT NEEDED IF THE "X" DIMENSION IS LESS THAN 24 mm IN THE NEW DOOR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door > Page 8251 GENERAL INFORMATION REGARDING SPACER USAGE The purpose of the spacer is to allow the flexibility of phasing in future lock designs without having to coordinate doors and locks in production or having to maintain two unique service doors. In general, the spacers are to be used with new doors (large hole) and old locks. The new doors are being phased in ahead of the new locks. PART NUMBER PART NAME F6TZ-1521890-AA Door Lock cylinder Spacer F6UZ-1521890-AA Door Lock Cylinder Spacer F68Z-1621890-AA Door Lock Cylinder Spacer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 111000, 112000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Locks: > 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Locks: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 8257 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Locks: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 8258 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Locks: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration Fluid - A/T: All Technical Service Bulletins A/T - Vibration/Shudder On Light Acceleration Article No. 95-23-4 11/20/95 FORD: 1992-95 CROWN VICTORIA 1994-95 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1992-95 GRAND MARQUIS, TOWN CAR 1993-95 MARK VIII 1994-95 COUGAR LIGHT TRUCK: 1994-95 ECONOLINE, F-150 This TSB article is being republished in its entirety to clarify Issue, Action, Service Procedure, and Operation. ISSUE: Torque converter clutch shudder or vibration may occur under light to moderate acceleration above 56 km/h (35 mph) while in 3rd or 4th gear or during 3-4 or 4-3 shifts. This condition may be noticeable on higher mileage vehicles (24,000 km/15,000 mi or more) when the torque converter clutch engages or disengages during light to moderate acceleration. ACTION: Perform normal diagnostics (i.e., linkage adjustment fluid level and condition, On-Board diagnostic check). If self test codes are present, service as required. If no DTCs are present, perform the following Service Procedure. SERVICE PROCEDURE 1. Drain all transmission fluid. Refer to the appropriate Service Manual, Section 07-01 for details. If fluid is burnt or heavily contaminated, repair as required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Locks: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 8263 2. Remove transmission and replace the torque converter assembly with the correct torque converter. Refer to Figure 1. 3. Remove the transmission pan and clean transmission pan and pan magnet. 4. Inspect transmission pan gasket and filter. Reuse both pan gasket and filter if not damaged. 5. Reinstall filter, pan magnet, and transmission pan with original gasket. 6. Completely clean and flush transmission cooler and cooler lines. 7. Reinstall the transmission assembly. 8. Refill transmission with Mercon(R) Automatic Transmission Fluid (XT-2-QDX). Use only quart containers of Mercon(R) when refilling to ensure proper fluid quality is being used. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Locks: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 8264 PART NUMBER PART NAME XT-2-QDX Mercon(R) Automatic Transmission Fluid F5AZ-7902-ARM Torque Converter F5ZZ-7902-ARM Torque Converter F4LY-7902-ARM Torque Converter F4SZ-7902-BRM Torque Converter Please use the following repair description for each model described in the OPERATION/DESCRIPTION/TIME section of this TSB article: Perform electronic transmission diagnostics, replace torque converter, drain and fill transmission (including inspection of filter - replace if necessary), flush cooler and lines. Road test vehicle after repairs are complete. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-14-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952304A 1994-95 Econoline 4.6 Hrs. 952304B 1994-95 F-Series 4X2 4.4 Hrs. 952304C 1994-95 F-Series 4X4 6.0 Hrs. 952304D 1994-95 Mustang 3.8L 5.1 Hrs. 952304E 1994-95 Mustang 5.0L 5.3 Hrs. 952304F 1994-95 5.4 Hrs. Thunderbird/Cougar 4.6L 952304G 1994-95 5.3 Hrs. Thunderbird/Cougar 3.8L 952304H 1993-95 Mark VIII 5.4 Hrs. 952304I 1992-95 Crown 4.9 Hrs. Victoria/Grand Marquis/Town Car DEALER CODING CONDITION BASIC PART NO. CODE 7902 67 OASIS CODES: 501000, 502000, 504000, 510000, 597997, 703000, 703200, 703400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Locks: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 8270 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Locks: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 8271 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Locks: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 8276 2. Remove transmission and replace the torque converter assembly with the correct torque converter. Refer to Figure 1. 3. Remove the transmission pan and clean transmission pan and pan magnet. 4. Inspect transmission pan gasket and filter. Reuse both pan gasket and filter if not damaged. 5. Reinstall filter, pan magnet, and transmission pan with original gasket. 6. Completely clean and flush transmission cooler and cooler lines. 7. Reinstall the transmission assembly. 8. Refill transmission with Mercon(R) Automatic Transmission Fluid (XT-2-QDX). Use only quart containers of Mercon(R) when refilling to ensure proper fluid quality is being used. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Other Service Bulletins for Door Locks: > 95234 > Nov > 95 > A/T - Vibration/Shudder On Light Acceleration > Page 8277 PART NUMBER PART NAME XT-2-QDX Mercon(R) Automatic Transmission Fluid F5AZ-7902-ARM Torque Converter F5ZZ-7902-ARM Torque Converter F4LY-7902-ARM Torque Converter F4SZ-7902-BRM Torque Converter Please use the following repair description for each model described in the OPERATION/DESCRIPTION/TIME section of this TSB article: Perform electronic transmission diagnostics, replace torque converter, drain and fill transmission (including inspection of filter - replace if necessary), flush cooler and lines. Road test vehicle after repairs are complete. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-14-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 952304A 1994-95 Econoline 4.6 Hrs. 952304B 1994-95 F-Series 4X2 4.4 Hrs. 952304C 1994-95 F-Series 4X4 6.0 Hrs. 952304D 1994-95 Mustang 3.8L 5.1 Hrs. 952304E 1994-95 Mustang 5.0L 5.3 Hrs. 952304F 1994-95 5.4 Hrs. Thunderbird/Cougar 4.6L 952304G 1994-95 5.3 Hrs. Thunderbird/Cougar 3.8L 952304H 1993-95 Mark VIII 5.4 Hrs. 952304I 1992-95 Crown 4.9 Hrs. Victoria/Grand Marquis/Town Car DEALER CODING CONDITION BASIC PART NO. CODE 7902 67 OASIS CODES: 501000, 502000, 504000, 510000, 597997, 703000, 703200, 703400 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations Remote Keyless Entry Module: Locations Full Body View (Part 2 Of 2) The Remote Keyless Entry Module is located behind LH "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations > Page 8282 Remote Keyless Entry Module: Diagrams Remote Keyless Entry Module (C333) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations > Page 8283 Remote Keyless Entry Module (C334) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Programming Connector > Component Information > Locations Keyless Entry Programming Connector: Locations Full Body View Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Programming Connector > Component Information > Locations > Page 8287 Location Of Keyless Entry Program Connector And Module. The Remote Keyless Entry Data Link Connector is located behind LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters Technical Service Bulletin # 95B79 Date: 950101 Campaign - Keyless Entry System Transmitters 95B79 OWNER NOTIFICATION PROGRAM Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program Dealer Letter Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Customer Notification Letter Attachment I - Admin./Labor and Parts Information FCSD Contact Talk with your FCSD Parts and Service Zone Manager about program concerns. Claims Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Labor Allowances OPERATION DESCRIPTION HOURS OPERATION Program RKE Transmitters 0.3 Hrs. B79B Parts Requirements There are no parts required for this special owner "mail-in" program. For owners returning with new transmitters and an authorization letter for a free engine oil and filter change claim for the following allowance: ^ Engine Oil and Filter Change Allowance - $25.00 ^ Enter $25.00 in MISC area of the claim as "OTHER" (Includes Labor, Parts and Markup) Claims Preparation Enter using DWE. Use code information shown below: ^ Program Code - 95B79 ^ Labor Operation - B79B See Sections 5 & 6 of the ACESII Manual for detailed instructions. Attachment II - Technical Information Remote Keyless Entry Transmitter Reprogramming NOTE: The reprogramming procedure is basically identical for all vehicles. Exceptions will be identified within each step. Remote Keyless Entry Transmitter Reprogramming 1. Locate the 2-pin RKE programming connector. Refer to RKE Programming Connector Location list below. 2. Turn ignition switch to the RUN position. 3. Using a jumper wire or alligator clip momentarily short the two terminals within the 2-pin program connector. On Econoline models you will need to short these terminals for the duration of the reprogramming procedure. The doors will lock then unlock on all models except Contour and Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 8296 Mystique. On Contour and Mystique models only the horn will sound and the exterior lights will flash. 4. Press any button on the remote keyless entry transmitter. All doors will lock then unlock to verify transmitter has been programmed. The horn will sound and the exterior lights will flash on the Contour and Mystique. NOTE: Programming in the first transmitter will erase all other previously programmed transmitters. All transmitters that are to operate with the vehicle (up to four transmitters) must be programmed during Steps 4 and 5. 5. Repeat Step 4 for any additional remote transmitters to be reprogrammed. 6. Turn ignition switch OFF. All doors should lock then unlock. On Contour and Mystique models the horn will sound and the exterior lights will flash. 7. Remove short (Econoline models only). 8. Install any trim previously removed. 9. Verify transmitter operation. RKE Programming Connector Location The Two-Pin RKE Programming Connector Is Located; Taurus/Sable Wagons - behind the left side trim panel inside the cargo area. Remove the trim panel for access to the connector. Taurus/Sable Sedans - Under the left side of the package tray. Contour/Mystique - under the right side of the instrument panel, behind right side of glove compartment. Reach up behind the glove compartment for access to the connector. Probe - in the trunk behind the subwoofer on the right side of the vehicle. Remove the subwoofer (if so equipped) for access to the connector. Mark VIII, Crown Victoria, Grand Marquis and Town Car - behind the glove compartment. Open the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. F-Series and Bronco - under the drivers side of the instrument panel above the drivers right foot area. Mustang - in the trunk behind the left side trim panel. Loosen the lining board (convertibles only) and the rear and left side trim covers to gain access to the connector. Thunderbird/Cougar - behind the left side trim panel inside the trunk. Remove the trim panel for access to the connector. Explorer - behind the left quarter utility compartment access panel. Remove the panel for access to the connector. Windstar - behind and to the right of the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. Econoline - under the instrument panel to the left of the steering column. Continental - under the right side of the instrument panel near the glove compartment. Remove the panel from beneath the instrument panel for access to the connector. For further information regarding connector location and color-coding refer to the appropriate Electrical Vacuum and Troubleshooting Manual (EVTM). Dealer Letter To: All Ford and Lincoln-Mercury Dealers Subject: Owner Notification Program 95B79 - Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program OASIS NO Owner List NO Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 8297 Parts Return NO Program Terms Available through October 31, 1996 Affected Vehicles 1994-model Continental, Explorer, Crown Victoria, Grand Marquis and Town Car, 1994 and 1995-model Mustang, Taurus, Sable, Thunderbird, Cougar, Mark VIII, Probe, F-Series, Bronco, Econoline and 1995-model Contour, Mystique and Windstar vehicles equipped with the factory installed remote keyless entry system option. (This is the rectangular-shaped transmitter, manufactured by TRW Corp.) Reason For This Program The remote keyless entry system transmitter positive battery terminal contact surface may develop corrosion and result in intermittent transmitter operation and/or unnecessary battery replacement. Service Action Owners of affected vehicles will be notified of a special "mail-in" up-grade program and will be instructed to return their transmitters in a special prepaid mailing envelope. The transmitters will be serviced at a central facility and returned to owners. This bulletin provides instructions if owners should return to dealers for service. Owners will use the special mailing envelope for this special "mail-in" service. However, there are two situations where an owner may contact their dealer: 1.) where the special mailing envelope cannot be located, or 2.) where the central servicing facility was unable to perform the required upgrade of the transmitter for technical reasons. Dealers are required to provide transmitter reprogramming service along with a free engine oil and filter change. In these situations customers will have received an authorization letter along with the new transmitters. Additionally, customers are informed that the authorization letter and the transmitters are to be presented when requesting this service. Limited-Time Program This special "mail-in" program will only be available through October 31, 1996. Special Toll-Free Number for Owner's Questions A special toll-free number is available for owners (1-800-490-4288) from 7:30 a.m. to 7:30 p.m. weekdays and 8:00 a.m. to 3:00 p.m. on Saturdays (All times are Eastern Time). Technical/Administrative Questions? Claims Information 1-800-423-8851 Other Program Questions 1-800-325-5621 Attachments Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Owner Letter Serial Number: xxxxxxxxxxxxxxxxx 95B79 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a special no-charge Service Program 95B79 to owners of certain 1994 and 1995-model vehicles equipped with the Ford Remote Keyless Entry System. Reason For This Program: Battery contact corrosion inside the small rectangular shaped Ford Remote Keyless Entry System transmitters (with your vehicle's keys) may cause the system to operate intermittently and possibly result in unnecessary battery replacement. No Charge Service With Drop-In-The-Mailbox Convenience: At no charge to you, Ford Motor Company will upgrade your remote transmitters for Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 8298 proper trouble-free operation via a special mail-in service program. This special mail-in program is designed to provide you with a quick, convenient way to upgrade your remote transmitters and is available to you through October 31, 1996. (If you desire, you could have this service performed by your Ford or Lincoln-Mercury dealer.) Return Transmitters In Special Prepaid Mailer: Use the enclosed prepaid mailing envelope to return all of your remote transmitters for the vehicle identified by the serial number above. Just drop the envelope (with the transmitters enclosed) in the mail. For your security and protection, the prepaid mailer does not require your name or address. The bar-coding on the label will enable us to identify you. Return Only The Transmitters: Please return the remote transmitters only. Detach them from the large key ring. (During the time that your transmitters are being upgraded, remember that you will have to use your key; we apologize for this inconvenience.) Processing Time: Counting mail time to and from our service center, we expect your transmitters will be returned to you within 10 working days. If you have not received your transmitters back by this time, please call the following toll-free number: 1-800-490-4288. Changed Address? Please fill-out the enclosed postcard with your new address and return it in the prepaid mailer with your transmitters. Sold Your Vehicle? Do nothing and discard this communication. Questions? A special toll-free number (1-800-490-4288) is available if you have questions on this program. Ford representatives are available weekdays from 7:30 a.m. to 7:30 p.m. and on Saturdays from 8:00 a.m. to 3:00 p.m. Eastern time. Have your vehicle serial number ready when you call. It is printed above. We are taking this action as part of our on-going efforts to maintain owner confidence in our products. We hope this special mail-in program will confirm your continued satisfaction with your Ford Remote Keyless Entry System. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters Technical Service Bulletin # 95B79 Date: 950101 Campaign - Keyless Entry System Transmitters 95B79 OWNER NOTIFICATION PROGRAM Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program Dealer Letter Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Customer Notification Letter Attachment I - Admin./Labor and Parts Information FCSD Contact Talk with your FCSD Parts and Service Zone Manager about program concerns. Claims Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Labor Allowances OPERATION DESCRIPTION HOURS OPERATION Program RKE Transmitters 0.3 Hrs. B79B Parts Requirements There are no parts required for this special owner "mail-in" program. For owners returning with new transmitters and an authorization letter for a free engine oil and filter change claim for the following allowance: ^ Engine Oil and Filter Change Allowance - $25.00 ^ Enter $25.00 in MISC area of the claim as "OTHER" (Includes Labor, Parts and Markup) Claims Preparation Enter using DWE. Use code information shown below: ^ Program Code - 95B79 ^ Labor Operation - B79B See Sections 5 & 6 of the ACESII Manual for detailed instructions. Attachment II - Technical Information Remote Keyless Entry Transmitter Reprogramming NOTE: The reprogramming procedure is basically identical for all vehicles. Exceptions will be identified within each step. Remote Keyless Entry Transmitter Reprogramming 1. Locate the 2-pin RKE programming connector. Refer to RKE Programming Connector Location list below. 2. Turn ignition switch to the RUN position. 3. Using a jumper wire or alligator clip momentarily short the two terminals within the 2-pin program connector. On Econoline models you will need to short these terminals for the duration of the reprogramming procedure. The doors will lock then unlock on all models except Contour and Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 8304 Mystique. On Contour and Mystique models only the horn will sound and the exterior lights will flash. 4. Press any button on the remote keyless entry transmitter. All doors will lock then unlock to verify transmitter has been programmed. The horn will sound and the exterior lights will flash on the Contour and Mystique. NOTE: Programming in the first transmitter will erase all other previously programmed transmitters. All transmitters that are to operate with the vehicle (up to four transmitters) must be programmed during Steps 4 and 5. 5. Repeat Step 4 for any additional remote transmitters to be reprogrammed. 6. Turn ignition switch OFF. All doors should lock then unlock. On Contour and Mystique models the horn will sound and the exterior lights will flash. 7. Remove short (Econoline models only). 8. Install any trim previously removed. 9. Verify transmitter operation. RKE Programming Connector Location The Two-Pin RKE Programming Connector Is Located; Taurus/Sable Wagons - behind the left side trim panel inside the cargo area. Remove the trim panel for access to the connector. Taurus/Sable Sedans - Under the left side of the package tray. Contour/Mystique - under the right side of the instrument panel, behind right side of glove compartment. Reach up behind the glove compartment for access to the connector. Probe - in the trunk behind the subwoofer on the right side of the vehicle. Remove the subwoofer (if so equipped) for access to the connector. Mark VIII, Crown Victoria, Grand Marquis and Town Car - behind the glove compartment. Open the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. F-Series and Bronco - under the drivers side of the instrument panel above the drivers right foot area. Mustang - in the trunk behind the left side trim panel. Loosen the lining board (convertibles only) and the rear and left side trim covers to gain access to the connector. Thunderbird/Cougar - behind the left side trim panel inside the trunk. Remove the trim panel for access to the connector. Explorer - behind the left quarter utility compartment access panel. Remove the panel for access to the connector. Windstar - behind and to the right of the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. Econoline - under the instrument panel to the left of the steering column. Continental - under the right side of the instrument panel near the glove compartment. Remove the panel from beneath the instrument panel for access to the connector. For further information regarding connector location and color-coding refer to the appropriate Electrical Vacuum and Troubleshooting Manual (EVTM). Dealer Letter To: All Ford and Lincoln-Mercury Dealers Subject: Owner Notification Program 95B79 - Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program OASIS NO Owner List NO Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 8305 Parts Return NO Program Terms Available through October 31, 1996 Affected Vehicles 1994-model Continental, Explorer, Crown Victoria, Grand Marquis and Town Car, 1994 and 1995-model Mustang, Taurus, Sable, Thunderbird, Cougar, Mark VIII, Probe, F-Series, Bronco, Econoline and 1995-model Contour, Mystique and Windstar vehicles equipped with the factory installed remote keyless entry system option. (This is the rectangular-shaped transmitter, manufactured by TRW Corp.) Reason For This Program The remote keyless entry system transmitter positive battery terminal contact surface may develop corrosion and result in intermittent transmitter operation and/or unnecessary battery replacement. Service Action Owners of affected vehicles will be notified of a special "mail-in" up-grade program and will be instructed to return their transmitters in a special prepaid mailing envelope. The transmitters will be serviced at a central facility and returned to owners. This bulletin provides instructions if owners should return to dealers for service. Owners will use the special mailing envelope for this special "mail-in" service. However, there are two situations where an owner may contact their dealer: 1.) where the special mailing envelope cannot be located, or 2.) where the central servicing facility was unable to perform the required upgrade of the transmitter for technical reasons. Dealers are required to provide transmitter reprogramming service along with a free engine oil and filter change. In these situations customers will have received an authorization letter along with the new transmitters. Additionally, customers are informed that the authorization letter and the transmitters are to be presented when requesting this service. Limited-Time Program This special "mail-in" program will only be available through October 31, 1996. Special Toll-Free Number for Owner's Questions A special toll-free number is available for owners (1-800-490-4288) from 7:30 a.m. to 7:30 p.m. weekdays and 8:00 a.m. to 3:00 p.m. on Saturdays (All times are Eastern Time). Technical/Administrative Questions? Claims Information 1-800-423-8851 Other Program Questions 1-800-325-5621 Attachments Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Owner Letter Serial Number: xxxxxxxxxxxxxxxxx 95B79 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a special no-charge Service Program 95B79 to owners of certain 1994 and 1995-model vehicles equipped with the Ford Remote Keyless Entry System. Reason For This Program: Battery contact corrosion inside the small rectangular shaped Ford Remote Keyless Entry System transmitters (with your vehicle's keys) may cause the system to operate intermittently and possibly result in unnecessary battery replacement. No Charge Service With Drop-In-The-Mailbox Convenience: At no charge to you, Ford Motor Company will upgrade your remote transmitters for Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 8306 proper trouble-free operation via a special mail-in service program. This special mail-in program is designed to provide you with a quick, convenient way to upgrade your remote transmitters and is available to you through October 31, 1996. (If you desire, you could have this service performed by your Ford or Lincoln-Mercury dealer.) Return Transmitters In Special Prepaid Mailer: Use the enclosed prepaid mailing envelope to return all of your remote transmitters for the vehicle identified by the serial number above. Just drop the envelope (with the transmitters enclosed) in the mail. For your security and protection, the prepaid mailer does not require your name or address. The bar-coding on the label will enable us to identify you. Return Only The Transmitters: Please return the remote transmitters only. Detach them from the large key ring. (During the time that your transmitters are being upgraded, remember that you will have to use your key; we apologize for this inconvenience.) Processing Time: Counting mail time to and from our service center, we expect your transmitters will be returned to you within 10 working days. If you have not received your transmitters back by this time, please call the following toll-free number: 1-800-490-4288. Changed Address? Please fill-out the enclosed postcard with your new address and return it in the prepaid mailer with your transmitters. Sold Your Vehicle? Do nothing and discard this communication. Questions? A special toll-free number (1-800-490-4288) is available if you have questions on this program. Ford representatives are available weekdays from 7:30 a.m. to 7:30 p.m. and on Saturdays from 8:00 a.m. to 3:00 p.m. Eastern time. Have your vehicle serial number ready when you call. It is printed above. We are taking this action as part of our on-going efforts to maintain owner confidence in our products. We hope this special mail-in program will confirm your continued satisfaction with your Ford Remote Keyless Entry System. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Remote Keyless Entry <--> [Keyless Entry] > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 8307 Keyless Entry Transmitter: Service and Repair To program (or reprogram) transmitter(s) into the electronic door lock control, perform the following steps: 1. Turn the ignition switch to the ON or ON/ACC position and momentarily short the two terminals of the program connector (C2), a two-pin connector located below the driver's side of the instrument panel at the base of the steering column. All doors should lock and then unlock. 2. Press any button on each transmitter. All doors should lock and then unlock. If the door locks do not respond, press the button again (up to three times maximum with the same transmitter). If the door locks still fail to respond, go to Pinpoint Test D. 3. Repeat Step 2 to program additional transmitters into the control module (up to four transmitters maximum). 4. Turn ignition switch off. All doors should lock and then unlock. 5. Make sure the short has been removed from the program connector C2. 6. Verify that the transmitters have been successfully programmed by pressing the LOCK or UNLOCK button on each transmitter, and observing that the system responds by locking and/or unlocking the doors. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Power Door Locks <--> [Power Locks] > Power Door Lock Control Module > Component Information > Locations Power Door Lock Control Module: Locations Full Body View (Part 2 Of 2) The Memory Lock Module is located behind LH "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Power Door Locks <--> [Power Locks] > Power Door Lock Control Module > Component Information > Locations > Page 8312 Memory Lock Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Power Door Locks <--> [Power Locks] > Power Door Lock Switch > Component Information > Diagrams > With Power Windows Power Door Lock Switch: Diagrams With Power Windows Master Window/Door Lock Control Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Power Door Locks <--> [Power Locks] > Power Door Lock Switch > Component Information > Diagrams > With Power Windows > Page 8317 RH Power Door Lock/Window Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Power Door Locks <--> [Power Locks] > Power Door Lock Switch > Component Information > Diagrams > With Power Windows > Page 8318 Power Door Lock Switch: Diagrams Without Power Windows LH Power Door Lock Switch LH Power Door Lock Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Locks > Power Door Locks <--> [Power Locks] > Power Door Lock Switch > Component Information > Diagrams > With Power Windows > Page 8319 RH Power Door Lock Switch RH Power Door Lock Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > With Door Trim Power Mirror Switch (With Door Trim) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > With Door Trim > Page 8325 Power Mirror Switch (Without Door Trim) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 8331 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 8332 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 8333 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 8334 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 8335 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 8336 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 8337 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 8338 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 8339 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 8340 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 8341 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations Remote Keyless Entry Module: Locations Full Body View (Part 2 Of 2) The Remote Keyless Entry Module is located behind LH "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations > Page 8346 Remote Keyless Entry Module: Diagrams Remote Keyless Entry Module (C333) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Remote Keyless Entry Module <--> [Keyless Entry Module] > Component Information > Locations > Page 8347 Remote Keyless Entry Module (C334) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations Power Door Lock Control Module: Locations Full Body View (Part 2 Of 2) The Memory Lock Module is located behind LH "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations > Page 8351 Memory Lock Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Driver's Seat Motor Assembly Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams Driver's Seat Regulator Control Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips Seat Cover: Technical Service Bulletins Seat Leather - Cleaning Procedure Tips Article No. 98-17-1 09/01/98 SEAT - LEATHER CLEANING PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 THUNDERBIRD 1984-98 CROWN VICTORIA, ESCORT, MUSTANG 1986-98 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1984-97 COUGAR 1984-98 GRAND MARQUIS, TRACER 1984-99 TOWN CAR 1986-98 SABLE 1993-98 MARK VIII 1995-98 MYSTIQUE 1995-99 CONTINENTAL 1999 COUGAR LIGHT TRUCK: 1983-98 RANGER 1984-96 BRONCO 1984-97 F-250 HD 1984-98 ECONOLINE, F-150, F-250 LD 1986-97 AEROSTAR 1991-98 EXPLORER 1993-98 VILLAGER 1996-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to include the latest level parts and to include a revised Service Procedure. ISSUE The following TSB contains information regarding the cleaning of interior leather seats and trim. Improper cleaning procedures may damage the leather. If seats are not cleaned on a regular basis (every 4-6 weeks), normal wear and tear can cause excessive soiling. ACTION Ford Motor Company has developed a new kit (Deluxe Leather Care Kit - F8AZ-19G253-AA) to clean soiled seats without damaging the top coat of the leather. The kit contains a leather and vinyl cleaner along with a specially formulated sponge. Refer to the text for cleaning leather seats and trim. The Deluxe Leather Care Kit has been tested and approved for use on all Ford and Lincoln/Mercury leather and vinyl seating surfaces, and if used as directed, should be used for service repairs. Many household cleaners and sponges are too harsh to be used on leather and may actually cause permanent damage to the surface. Use this material on leather and vinyl seats that: ^ show excessive soiling ^ have been stained with coffee, lipstick, etc. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips > Page 8363 Refer to the instructions included in the kit for specific application procedures. After cleaning surface with cleaner and sponge, wipe area with water and a cotton cloth. NOTE AVOID EXCESSIVE APPLICATION OF CLEANER ALONG STITCHING. PART NUMBER PART NAME F8AZ-19G253-AA Deluxe Leather Care Kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 101000, 107000, 190000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > Customer Interest: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: Customer Interest Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 961215 > Mar > 96 > Alarm System - Sounds in Error Anti-Theft Hood Switch: All Technical Service Bulletins Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Anti-Theft Hood Switch: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly Camshaft Position Sensor: All Technical Service Bulletins Engine Controls - Low RPM, No Start, Runs Poorly Article No. 03-21-23 10/06/03 DRIVEABILITY - LOW RPM - NO START - RUNS POORLY - STALL - 7.3L DIT ENGINE FORD: 1994-1997 F SUPER DUTY, F-250, F-350 1995-1997 E-350 Article 97-6-18 is being republished with updates as part of a consolidated 7.3L diagnostic aid booklet. ISSUE The 7.3L Direct Injection Turbo (DIT) engines are built with 0.1016-0.8128 mm (0.0040-0.032") clearance between the Camshaft Position (CMP) Sensor and the trigger wheel. At approximately 1.016 mm (0.040") clearance, the sensor will fail to synchronize and result in a no run condition. Improper CMP clearance can be seen in the following six (6) symptoms: ^ 1) Fault codes - incorrect synchronization count ^ 2) Low RPM - fails to achieve rated speed for 2-3 minutes after extended cold soak ^ 3) No start - after extended cold soak ^ 4) Runs poorly cold - engine runs OK warm ^ 5) Stall on deceleration - more pronounced cold ^ 6) Starts, runs cold, dies warm, will not restart until cool ACTION Install a shim between the CMP sensor and the front engine cover. The shim will allow the correct clearance which should reduce the possibility of concerns. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal DIT Powerstroke diagnostics. If no other problems are found, proceed with this TSB article. 2. Remove CMP sensor and inspect for signs of contact with the pulse wheel. Make sure the holes on the end are filled with epoxy and inspect the connector mating cavity for signs of oil contamination. If there are any signs of contact, contamination, or the holes are not filled, replace the CMP Sensor (F6TZ-12K073-A). 3. Repair symptoms 1) - 5) as follows: install a 0.254 mm (0.010") shim under the CMP sensor. If symptoms persist, increase the shim thickness to 0.508 mm (0.020") Shim (F7TZ-1 2J072-AA). NOTE SOME ENGINES BETWEEN SERIAL NUMBERS 388840 AND 410010 HAVE BEEN BUILT WITH EXCESSIVE AMOUNTS OF TRIGGER WHEEL RUNOUT. RUNOUT OF THE TRIGGER WHEEL GREATER THAN 0.508 mm (0.020") MIGHT NOT BE RESOLVED WITH A SHIM. THE ADDITIONAL CLEARANCE CAN PUT TOTAL CLEARANCE ABOVE 1.016 mm (0.040") AND CAUSE FAILURE TO SYNCHRONIZE. 4. If symptom 6) occurs and trigger wheel runout is greater than 0.508 mm (0.020"), try a 0.254 mm (0.010") shim. If the concern is unresolved, replace the Camshaft Assembly (F4TZ-6250-A). Refer to the appropriate model/year Service Manual, Section 03-01C, for camshaft assembly replacement procedure. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Anti-Theft Hood Switch: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 8384 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Anti-Theft Hood Switch <--> [Hood Sensor/Switch (For Alarm)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Anti-Theft Hood Switch: > 03-21-23 > Oct > 03 > Engine Controls - Low RPM, No Start, Runs Poorly > Page 8390 PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-6-18 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement Part Article No. 01-19-4 10/01/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES 1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 201000, 201200 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > With Power Windows Power Door Lock Switch: Diagrams With Power Windows Master Window/Door Lock Control Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > With Power Windows > Page 8399 RH Power Door Lock/Window Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > With Power Windows > Page 8400 Power Door Lock Switch: Diagrams Without Power Windows LH Power Door Lock Switch LH Power Door Lock Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > With Power Windows > Page 8401 RH Power Door Lock Switch RH Power Door Lock Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > With Door Trim Power Mirror Switch (With Door Trim) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > With Door Trim > Page 8406 Power Mirror Switch (Without Door Trim) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Driver's Seat Regulator Control Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8418 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8419 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8420 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 97-14-22 > Jul > 97 > Doors - (60/40) Noise While Vehicle is in Motion Weatherstrip: Customer Interest Doors - (60/40) Noise While Vehicle is in Motion Article No. 97-14-22 07/07/97 NOISE - "SQUEAKING" NOISE FROM 60/40 DOOR WHILE DRIVING - VEHICLES BUILT THROUGH 5/30/97 LIGHT TRUCK: 1995-97 ECONOLINE ISSUE: There may be a "squeaking" noise coming from the 60/40 doors while driving. This may be caused by the body flex causing the doors to rub on the weatherstrip, resulting in a squeak. ACTION: Replace the 60/40 door weatherstrip with new weatherstrip. The new weatherstrip uses a different coating that will reduce the friction between the door and weatherstrip, reducing the possibility of squeak. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Open the 60/40 doors and remove stepwell from the door opening. 2. Remove the door opening weatherstrip. NOTE: DO NOT REMOVE THE PULL CORD FROM THE NEW WEATHERSTRIP PRIOR TO INSTALLATION. 3. Install new weatherstrip starting from the lower B-pillar. Working in a counterclockwise direction, press weatherstrip into place. 4. Remove Pull cord from new weatherstrip to allow weatherstrip to properly seat over interior trim. 5. Reinstall the door opening stepwell. PART NUMBER PART NAME F7UZ-15253A10-AA Weatherstrip OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971422A Replace Weatherstrip 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 15253A10 41 OASIS CODES: 107000, 110000, 702000, 702300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8430 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8431 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 8432 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 97-14-22 > Jul > 97 > Doors - (60/40) Noise While Vehicle is in Motion Weatherstrip: All Technical Service Bulletins Doors - (60/40) Noise While Vehicle is in Motion Article No. 97-14-22 07/07/97 NOISE - "SQUEAKING" NOISE FROM 60/40 DOOR WHILE DRIVING - VEHICLES BUILT THROUGH 5/30/97 LIGHT TRUCK: 1995-97 ECONOLINE ISSUE: There may be a "squeaking" noise coming from the 60/40 doors while driving. This may be caused by the body flex causing the doors to rub on the weatherstrip, resulting in a squeak. ACTION: Replace the 60/40 door weatherstrip with new weatherstrip. The new weatherstrip uses a different coating that will reduce the friction between the door and weatherstrip, reducing the possibility of squeak. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Open the 60/40 doors and remove stepwell from the door opening. 2. Remove the door opening weatherstrip. NOTE: DO NOT REMOVE THE PULL CORD FROM THE NEW WEATHERSTRIP PRIOR TO INSTALLATION. 3. Install new weatherstrip starting from the lower B-pillar. Working in a counterclockwise direction, press weatherstrip into place. 4. Remove Pull cord from new weatherstrip to allow weatherstrip to properly seat over interior trim. 5. Reinstall the door opening stepwell. PART NUMBER PART NAME F7UZ-15253A10-AA Weatherstrip OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 971422A Replace Weatherstrip 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 15253A10 41 OASIS CODES: 107000, 110000, 702000, 702300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake ON/OFF Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > NHTSA 06V286000 > Jul > 06 > Recall 06V286000: Cruise Control Switch Fire Hazard Brake ON/OFF Switch: Recalls Recall 06V286000: Cruise Control Switch Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/E450 1996-2002 Ford/Econoline 1994-1996 Ford/Excursion 2000-2002 Ford/Explorer 1998 Ford/F250 1994-2002 Ford/F350 1994-2002 Ford/F450 1994-2002 Ford/F550 1994-2002 Ford/Mountaineer 1998 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 06V286000 MFG'S REPORT DATE: July 27, 2006 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 1200000 SUMMARY: On certain trucks equipped with speed control, gasoline or natural gas engines, the speed control deactivation switch may overheat. CONSEQUENCE: Overheat could result in smoke, or burn and in an underhood fire. REMEDY: Dealers will install a fused wiring harness into the speed control system free of charge. The recall is expected to begin on August 7, 2006. Owners may contact Ford at 1-866-436-7332. NOTES: Ford recall No. 05S28. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake ON/OFF Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA 06V286000 > Jul > 06 > Recall 06V286000: Cruise Control Switch Fire Hazard Brake ON/OFF Switch: All Technical Service Bulletins Recall 06V286000: Cruise Control Switch Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/E450 1996-2002 Ford/Econoline 1994-1996 Ford/Excursion 2000-2002 Ford/Explorer 1998 Ford/F250 1994-2002 Ford/F350 1994-2002 Ford/F450 1994-2002 Ford/F550 1994-2002 Ford/Mountaineer 1998 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 06V286000 MFG'S REPORT DATE: July 27, 2006 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 1200000 SUMMARY: On certain trucks equipped with speed control, gasoline or natural gas engines, the speed control deactivation switch may overheat. CONSEQUENCE: Overheat could result in smoke, or burn and in an underhood fire. REMEDY: Dealers will install a fused wiring harness into the speed control system free of charge. The recall is expected to begin on August 7, 2006. Owners may contact Ford at 1-866-436-7332. NOTES: Ford recall No. 05S28. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake ON/OFF Switch: > 95212 > Jan > 95 > A/T E4OD Shift Concerns/DTC's Set Transmission Position Switch/Sensor: All Technical Service Bulletins A/T - E4OD Shift Concerns/DTC's Set Article No. 95-2-12 01/30/95 ^ TRANSMISSION - E40D - DIAGNOSTIC TROUBLE CODES - WATER INTRUSION OF THE MLP/TR SENSOR ^ TRANSMISSION - E40D - POSSIBLE WATER INTRUSION INTO THE MLP/TR SENSOR CAUSING SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS ^ TRANSMISSlON - E40D - SHIFT CONCERNS AND/OR HARSH ENGAGEMENT CONCERNS DUE TO WATER INTRUSION OF THE MLP/TR SENSOR LIGHT TRUCK: 1989-94 BRONCO, ECONOLINE, F-150-350 SERIES, F-47, F-53, F-59 ISSUE: Some vehicles may exhibit a shift concern and/or a harsh engagement concern due to water intrusion into the MLP/TR sensor and vehicle harness. There may also be a number of different DTC's along with those concerns. ACTION: Replace the MLP/TR sensor and vehicle harness connector if signs of water penetration are evident. Refer to the following for service details. SERVICE PROCEDURE 1. Verify the customer concern. 2. Perform normal on-board diagnostics. 3. Inspect the MLP/TR sensor for signs of water contamination. 4. If water penetration is present and/or DTC's have been set, replace the MLP/TR sensor and the vehicle harness connector with the TR Sensor Service Kit (F5TZ-7A247-A). The TR Service Kit contains: ^ One (1) TR Sensor ^ One (1) Connector Assembly ^ One (1) "Red" Pin Separator Plate ^ One (1) 6-Pin Grommet ^ One (1) 8-Pin Grommet ^ One (1) 7-Pin Grommet ^ One (1) Instruction Sheet PART NUMBER PART NAME F5TZ-7A247-A TR Sensor Service Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950212A Perform Electronic 2.0 Hrs. Transmission Diagnostics, Replace MLP/TR Sensor DEALER CODING BASIC PART NO. CONDITION CODE 7F293 08 OASIS CODES: 206000, 501000, 502000, 503000, 698298 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Page 8469 Brake ON/OFF Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8478 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8479 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8480 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8481 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8482 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8483 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8484 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8485 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8486 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8487 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8488 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8489 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8490 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8491 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8492 Owner Letter Owner Letter not available at this time. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8498 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8499 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8500 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8501 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8502 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8503 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8504 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8505 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8506 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8507 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8508 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8509 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8510 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8511 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8512 Owner Letter Owner Letter not available at this time. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Page 8513 Clutch Switch: Service and Repair 1. Disconnect deactivator switch electrical connector. 2. Unscrew switch to remove. 3. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 8527 Cruise Control Switch: Service and Repair 1. Disable air bag system. 2. Remove four air bag module to steering wheel attaching nuts, then lift module rearward from steering wheel. 3. Disconnect air bag electrical connector from clockspring contact connector. 4. Remove air bag module from steering wheel. NOTE: Position air bag module on bench with trim cover facing upward. 5. Disconnect horn/speed control black wire harness connector from clockspring contact connector located in upper center of steering wheel. 6. Remove two steering column switch attaching screws. 7. Remove electrical tape from electrical connectors located at each upper clip in steering wheel. 8. Disconnect speed control switch wires at untapped wire connectors, then remove switches. 9. Reverse procedure to install. Torque air bag module to steering wheel nut and washer assemblies to 35-53 in lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake ON/OFF Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Recalls: > NHTSA 06V286000 > Jul > 06 > Recall 06V286000: Cruise Control Switch Fire Hazard Brake ON/OFF Switch: Recalls Recall 06V286000: Cruise Control Switch Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/E450 1996-2002 Ford/Econoline 1994-1996 Ford/Excursion 2000-2002 Ford/Explorer 1998 Ford/F250 1994-2002 Ford/F350 1994-2002 Ford/F450 1994-2002 Ford/F550 1994-2002 Ford/Mountaineer 1998 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 06V286000 MFG'S REPORT DATE: July 27, 2006 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 1200000 SUMMARY: On certain trucks equipped with speed control, gasoline or natural gas engines, the speed control deactivation switch may overheat. CONSEQUENCE: Overheat could result in smoke, or burn and in an underhood fire. REMEDY: Dealers will install a fused wiring harness into the speed control system free of charge. The recall is expected to begin on August 7, 2006. Owners may contact Ford at 1-866-436-7332. NOTES: Ford recall No. 05S28. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake ON/OFF Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA 06V286000 > Jul > 06 > Recall 06V286000: Cruise Control Switch Fire Hazard Brake ON/OFF Switch: All Technical Service Bulletins Recall 06V286000: Cruise Control Switch Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/E450 1996-2002 Ford/Econoline 1994-1996 Ford/Excursion 2000-2002 Ford/Explorer 1998 Ford/F250 1994-2002 Ford/F350 1994-2002 Ford/F450 1994-2002 Ford/F550 1994-2002 Ford/Mountaineer 1998 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 06V286000 MFG'S REPORT DATE: July 27, 2006 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 1200000 SUMMARY: On certain trucks equipped with speed control, gasoline or natural gas engines, the speed control deactivation switch may overheat. CONSEQUENCE: Overheat could result in smoke, or burn and in an underhood fire. REMEDY: Dealers will install a fused wiring harness into the speed control system free of charge. The recall is expected to begin on August 7, 2006. Owners may contact Ford at 1-866-436-7332. NOTES: Ford recall No. 05S28. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake ON/OFF Switch: > 9599 > May > 95 > Thermactor System - Buzzing Noise Air Injection Muffler: All Technical Service Bulletins Thermactor System - Buzzing Noise Article No. 95-9-9 05/08/95 ^ THERMACTOR SYSTEM - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY ^ NOISE - "BUZZING" - 25-40 MPH IN 2ND OR 3RD GEAR - THERMACTOR SYSTEM OPERATING IN DUMP MODE - 1994 VEHICLES WITH 5.8L ENGINE AND 50 STATE CALIBRATION - 1995 VEHICLES WITH 5.8L ENGINE AND 49 STATE CALIBRATION ONLY LIGHT TRUCK: 1994-95 E-350 ISSUE: A "buzzing" noise may be heard between 25-40 mph while in 2nd or 3rd gear. This may be caused by air flow through the thermactor system during operation in dump mode. ACTION: Replace the air supply bypass valve hose with a cap on the intake air duct and install a thermactor silencer and bracket assembly. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the air dump hose which connects the thermactor bypass valve to the fresh air intake air duct. 2. Cap the open nipple on the intake air duct with a Rubber Cap (C6AZ-9486-A). No clamps are necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake ON/OFF Switch: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 8555 3. Install one (1) end of the Air Supply Pump Silencer Hose (F4TZ-9H458-A) onto the Silencer and Bracket Assembly (F4TZ-9H467-B) and secure with a Crimp Clamp (F1HZ-9H447-AA). Refer to Figure 1. 4. Remove the bolt from the engine installed thermactor assembly and install silencer and hose assembly. Refer to Figure 1. 5. Reinstall the bolt and torque to 11-19 N-m (8-14 lb.ft.). No clamp is necessary at the end of the hose. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake ON/OFF Switch: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 8556 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950909A Replace Air Dump Hose 0.4 Hr. With Cap And Install Silencer Assembly DEALER CODING CONDITION BASIC PART NO. CODE 9F870 56 OASIS CODES: 403000, 702000, 702300, 703000, 703300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake ON/OFF Switch: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 8562 3. Install one (1) end of the Air Supply Pump Silencer Hose (F4TZ-9H458-A) onto the Silencer and Bracket Assembly (F4TZ-9H467-B) and secure with a Crimp Clamp (F1HZ-9H447-AA). Refer to Figure 1. 4. Remove the bolt from the engine installed thermactor assembly and install silencer and hose assembly. Refer to Figure 1. 5. Reinstall the bolt and torque to 11-19 N-m (8-14 lb.ft.). No clamp is necessary at the end of the hose. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake ON/OFF Switch: > 9599 > May > 95 > Thermactor System - Buzzing Noise > Page 8563 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950909A Replace Air Dump Hose 0.4 Hr. With Cap And Install Silencer Assembly DEALER CODING CONDITION BASIC PART NO. CODE 9F870 56 OASIS CODES: 403000, 702000, 702300, 703000, 703300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake ON/OFF Switch <--> [Brake Switch (Cruise Control)] > Component Information > Technical Service Bulletins > Page 8564 Brake ON/OFF Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8573 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8574 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8575 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8576 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8577 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8578 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8579 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8580 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8581 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8582 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8583 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8584 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8585 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8586 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8587 Owner Letter Owner Letter not available at this time. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8593 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8594 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8595 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8596 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8597 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8598 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8599 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8600 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8601 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8602 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8603 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8604 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8605 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8606 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 8607 Owner Letter Owner Letter not available at this time. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Page 8608 Clutch Switch: Service and Repair 1. Disconnect deactivator switch electrical connector. 2. Unscrew switch to remove. 3. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 8622 Cruise Control Switch: Service and Repair 1. Disable air bag system. 2. Remove four air bag module to steering wheel attaching nuts, then lift module rearward from steering wheel. 3. Disconnect air bag electrical connector from clockspring contact connector. 4. Remove air bag module from steering wheel. NOTE: Position air bag module on bench with trim cover facing upward. 5. Disconnect horn/speed control black wire harness connector from clockspring contact connector located in upper center of steering wheel. 6. Remove two steering column switch attaching screws. 7. Remove electrical tape from electrical connectors located at each upper clip in steering wheel. 8. Disconnect speed control switch wires at untapped wire connectors, then remove switches. 9. Reverse procedure to install. Torque air bag module to steering wheel nut and washer assemblies to 35-53 in lb. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions ABS Light: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 8628 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 8629 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 8630 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 8631 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 8632 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 8633 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 8634 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 8635 ABS Light: Electrical Diagrams Brake Warning Indicator Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Chime <--> [Audible Warning Device] > Component Information > Diagrams > Diagram Information and Instructions Warning Chime: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Chime <--> [Audible Warning Device] > Component Information > Diagrams > Diagram Information and Instructions > Page 8640 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Chime <--> [Audible Warning Device] > Component Information > Diagrams > Diagram Information and Instructions > Page 8641 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Chime <--> [Audible Warning Device] > Component Information > Diagrams > Diagram Information and Instructions > Page 8642 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Chime <--> [Audible Warning Device] > Component Information > Diagrams > Diagram Information and Instructions > Page 8643 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Chime <--> [Audible Warning Device] > Component Information > Diagrams > Diagram Information and Instructions > Page 8644 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Chime <--> [Audible Warning Device] > Component Information > Diagrams > Diagram Information and Instructions > Page 8645 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Chime <--> [Audible Warning Device] > Component Information > Diagrams > Diagram Information and Instructions > Page 8646 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Chime <--> [Audible Warning Device] > Component Information > Diagrams > Diagram Information and Instructions > Page 8647 Warning Chime Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Buzzer Module <--> [Audible Warning Device Control Module] > Component Information > Locations Warning Buzzer Module: Locations Full Body View (Part 2 Of 2) The Warning Buzzer Module is located below LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Buzzer Module <--> [Audible Warning Device Control Module] > Component Information > Locations > Page 8651 Warning Buzzer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation Service Brakes The brake warning light in the instrument cluster is used to warn of system malfunctions. The red warning light for the brakes can indicate three conditions: The parking brake is not fully released. - The brake fluid level is low in the master cylinder reservoir. - The vacuum pressure is low on diesel engine vehicles. Diesel vehicles use a low vacuum indicator switch. The low vacuum indicator switch is located on the left side of the engine compartment near the vacuum pump. The low vacuum indicator switch will turn on the brake warning lamp when a low vacuum situation occurs. Rear Anti-Lock Brakes The yellow anti-lock brake indicator lights up for approximately two seconds when the key is first moved to RUN or START for circuit proveout. The indicator also lights up when the RABS module detects a malfunction in the system. The self-test feature contains codes that indicate the area of the malfunction. When a malfunction is detected, the RABS control module shuts down the system and the yellow anti-lock warning indicator comes on. This permits normal braking. A code can be retrieved by momentarily grounding the diagnostic pigtail (black with orange stripe wire) after it is disconnected from KAM (keep-alive power red wire) and counting the flashes of the yellow ABS lamp. To make sure the diagnostic trouble code (DTC) is not lost from memory, the key must be left in the RUN position before the diagnostic lead is disconnected from KAM power. If more than one diagnostic trouble code exists, only the first code stored will be displayed. Additional codes will be output only after the first fault is corrected. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation Charge Lamp/Indicator: Description and Operation PURPOSE To alert the vehicle operator of a charging system malfunction when the charge at the alternator falls below the normal operating range. OPERATION When the ignition switch is in START or RUN position, battery current flows through the alternator warning indicator into regulator at terminal 1 and to ground through the indicator switch. The electronic control measures a low voltage at terminal A and closes the field switch. This applies battery voltage to the field through alternator terminal F. With current in the field and the rotor turning, alternator stator produces a voltage at terminals B and S. A predetermined voltage at terminal S operates the electronic control to open indicator switch, which removes ground from alternator warning indicator. Alternator current output is controlled by current in the field. Average field current depends on length of time field switch is closed. The electronic control closes field switch when voltage at terminal A is low and opens switch when voltage is high. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > Page 8658 Charge Lamp/Indicator: Testing and Inspection TROUBLESHOOTING 1. If alternator indicator lamp does not light with ignition in ON position and engine not running, check condition of indicator lamp bulb. If bulb is satisfactory, check for an open in circuit between ignition switch and regulator terminal. 2. If alternator indicator lamp does not light, disconnect electrical connector from regulator and connect a jumper wire between 1 terminal of regulator electrical connector and negative battery post cable clamp. With ignition turned to ON position, indicator lamp should light. 3. If lamp does not light, check condition of indicator lamp bulb. If bulb is satisfactory, repair open in circuit between ignition switch and regulator or replace 500 ohm resistor (if equipped) across indicator lamp, as necessary. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8663 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8664 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8665 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8666 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8667 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8668 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8669 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8670 Cigar Lighter Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 8671 Cigarette Lighter: Description and Operation The cigar lighter element has a low resistance heating coil which operates much like the coil used in a portable heater. When the element is pushed completely in, the circuit is closed and current flows through the heating coil to the ground. When sufficient heat is generated, the element will overcome the spring pressure of the bimetal retaining fingers and be released. Instrument panel ash receptacles and cigar lighter knob and elements are located in the center of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Cigarette Lighter: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the cigar lighter. 2. Visually inspect the components of the cigar lighter system. VISUAL INSPECTION CHART Mechanical - Damaged retaining fingers Electrical - Blown fuse: - 15A AUDIO - Damaged wiring harness - Loose or corroded connections - Damaged element 3. Check the wiring harness for obvious signs of shorts, opens, bad connections, or damage. 4. If fault is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8674 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8675 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8676 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Testing and Inspection > Page 8677 Cigarette Lighter: Service and Repair Removal and Installation 1. Remove the cigar lighter knob and element. 2. Remove instrument panel finish panel. 3. Disconnect the push-on connectors from cigar lighter socket and retainer. 4. Unscrew the cigar lighter socket and retainer and remove from the instrument panel finish panel. 5. For installation, follow removal procedures in reverse order. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Testing and Inspection > Page 8678 Cigarette Lighter: Tools and Equipment Digital Volt-Ohmmeter ......................................................................................................................... ................................................................ 014-00407 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver side air bag module connector. 5. Connect Rotunda Air Bag Simulator 105-00010 or equivalent to vehicle harness at top of steering wheel. 6. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. REACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute for backup power supply to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. Reconnect driver air bag module connector. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten nut and washer assemblies 4-6 Nm (36-53 lb-in). 4. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 5. Prove out system. Refer to System Prove Out Procedure under Testing and Inspection / Procedures / Diagnostic Strategies. WARNING: THE AIR BAG SIMULATOR(S) MUST BE REMOVED AND THE DRIVER SIDE AIR BAG MODULE RECONNECTED FOR THE SYSTEM TO BE REACTIVATED. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8684 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Are center sensor and frame rail sensor connected and mounted to vehicle? ........................................................................................................... [ ] 2. Is right cowl side sensor connected and mounted to vehicle? ................................................................................................................................... [ ] 3. Is gray three-way connector at base of steering column connected? ........................................................................................................................ [ ] 4. Is air bag or air bag simulator connected? ...................................................................................... .......................................................................... [ ] 5. Is air bag diagnostic monitor connected? ........................................................................................ ......................................................................... [ ] 6. Is vehicle battery connected? .......................................................................................................... .......................................................................... [ ] Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filter Restriction Sensor > Component Information > Description and Operation Fuel Filter Restriction Sensor: Description and Operation The 7.3L diesel engine is equipped with a fuel filter restriction sensor. A restriction indicator light is provided on the instrument panel (04320) to alert the operator. If the restriction indicator light goes on during normal operation, the fuel filter should be changed as soon as practical. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation MAGNETIC FUEL INDICATOR This fuel level indicating system consists of a sending unit attached to the fuel tank and a fuel gauge mounted on the instrument panel. The magnetic fuel indicator gauge creates a polarity in the wire windings which, depending on the resistance at the sender, controls the degree of pointer rotation. This gauge operates on battery voltage. The fuel sender consists of a variable resistor, controlled by the action of an attached float in the fuel tank. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 8691 Fuel Gauge: Testing and Inspection Troubleshooting Chart, Fuel Level Reads Inaccurate Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 8692 Troubleshooting Chart, Fuel Level Reads Inaccurate Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 8693 Troubleshooting Chart, Fuel Level Reads Inaccurate Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming DEACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver side air bag module connector. 5. Connect Rotunda Air Bag Simulator 105-00010 or equivalent to vehicle harness at top of steering wheel. 6. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. REACTIVATION PROCEDURE 1. Disconnect battery positive cable. 2. Wait one minute for backup power supply to deplete stored energy. 3. Remove air bag simulator from vehicle harness connector at top of steering column. Reconnect driver air bag module connector. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten nut and washer assemblies 4-6 Nm (36-53 lb-in). 4. Connect battery positive cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 5. Prove out system. Refer to System Prove Out Procedure under Testing and Inspection / Procedures / Diagnostic Strategies. WARNING: THE AIR BAG SIMULATOR(S) MUST BE REMOVED AND THE DRIVER SIDE AIR BAG MODULE RECONNECTED FOR THE SYSTEM TO BE REACTIVATED. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8699 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Are center sensor and frame rail sensor connected and mounted to vehicle? ........................................................................................................... [ ] 2. Is right cowl side sensor connected and mounted to vehicle? ................................................................................................................................... [ ] 3. Is gray three-way connector at base of steering column connected? ........................................................................................................................ [ ] 4. Is air bag or air bag simulator connected? ...................................................................................... .......................................................................... [ ] 5. Is air bag diagnostic monitor connected? ........................................................................................ ......................................................................... [ ] 6. Is vehicle battery connected? .......................................................................................................... .......................................................................... [ ] Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp - A/T > Component Information > Description and Operation Malfunction Indicator Lamp - A/T: Description and Operation Transmission Control Indicator (TCIL) DESCRIPTION Indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation PURPOSE To alert the vehicle operator that the engine oil level is low. COMPONENTS The system consists of a float-type sensor mounted to the side of the engine oil pan, an electronic control module, and an instrument panel warning lamp. OPERATION The Check Oil Indicator will light with ignition switch in the START position as a bulb prove-out. When ignition switch is turned to RUN or START position, the control module determines whether sensor is grounded (oil low) or ungrounded (oil not low). If oil level is adequate, light will go out in RUN. If oil level is approximately 1.5 quarts or more low, the relay turns the warning lamp ON. The lamp will remain ON until ignition is turned OFF. After ignition is turned OFF, module will not reset for approximately five minutes. This delay allows time for oil drain back before another reading is allowed to occur. If engine is restarted during this delay period, the last reading will be displayed. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Description and Operation > Page 8706 Oil Level Warning Indicator: Testing and Inspection With oil level at FULL mark on oil dipstick and engine oil warm to assure that oil drains properly from oil sensor, turn ignition ON and start engine. Warning lamp should come on briefly in START for bulb test, then go out. Turn engine OFF. Drain two quarts of oil from engine. Wait approximately five minutes, then restart engine. Warning lamp should come on and stay on. If warning lamp does not come on check fuse, low oil level relay, low oil level sensor and lamp. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation Fig. 8 Magnetic Guage The magnetic gauge movement consists of three primary coils, one of which is wound at a 90 degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet which is attached to a shaft and pointer rotates to align to this primary field resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which is attached to the instrument cluster. These gauges require no adjustments, calibrations or maintenance. This gauge system does not use an IVR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests Oil Pressure Gauge: Pinpoint Tests Troubleshooting Chart, Oil Pressure Reads Inaccurate. Troubleshooting Chart, Oil Pressure Reads Inaccurate. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 8712 Oil Pressure Gauge: Component Tests and General Diagnostics TROUBLESHOOTING Tester tool No. 021-00055 or equivalent should be used to diagnose these type of gauges. When troubleshooting, refer to pertaining pinpoint test. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) 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 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 engine is idling, even though oil pressure is adequate. However, light should go out when engine speed is increased. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Warning Buzzer Module <--> [Audible Warning Device Control Module] > Component Information > Locations Warning Buzzer Module: Locations Full Body View (Part 2 Of 2) The Warning Buzzer Module is located below LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Warning Buzzer Module <--> [Audible Warning Device Control Module] > Component Information > Locations > Page 8720 Warning Buzzer Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Speedometer Data Link Connector > Component Information > Locations Speedometer Data Link Connector: Locations Instrument Panel View The PSOM Data Link Connector is located behind left side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation SEAT BELT WARNING SYSTEM The continuous-loop system units incorporate a safety belt warning indicator switch warning light and chime. The warning light and chime function as reminders to fasten the safety belt. If the safety belt is not buckled when the key is turned to the ON position, the light and chime will turn on for 4-8 seconds. - If the safety belt is buckled while the light is on and the chime is sounding, both light and chime will turn off. - If safety belt is buckled before the key is turned to the ON position, the light will come on for 4-8 seconds with no chime. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation SEAT BELT WARNING SYSTEM The continuous-loop system units incorporate a safety belt warning indicator switch warning light and chime. The warning light and chime function as reminders to fasten the safety belt. If the safety belt is not buckled when the key is turned to the ON position, the light and chime will turn on for 4-8 seconds. - If the safety belt is buckled while the light is on and the chime is sounding, both light and chime will turn off. - If safety belt is buckled before the key is turned to the ON position, the light will come on for 4-8 seconds with no chime. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Filter Restriction Sensor > Component Information > Description and Operation Fuel Filter Restriction Sensor: Description and Operation The 7.3L diesel engine is equipped with a fuel filter restriction sensor. A restriction indicator light is provided on the instrument panel (04320) to alert the operator. If the restriction indicator light goes on during normal operation, the fuel filter should be changed as soon as practical. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations Water In Fuel Sensor: Locations Engine View The Water In Fuel Sensor is located at the top LH side of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Speedometer Data Link Connector > Component Information > Locations Speedometer Data Link Connector: Locations Instrument Panel View The PSOM Data Link Connector is located behind left side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation Fig. 8 Magnetic Guage The magnetic gauge movement consists of three primary coils, one of which is wound at a 90 degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet which is attached to a shaft and pointer rotates and aligns to this primary field resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which is attached to the instrument cluster. These gauges require no adjustments, calibrations or maintenance. This gauge system does not use an IVR. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests Temperature Gauge: Pinpoint Tests Troubleshooting Chart, Temperature Gauge Inaccurate. Troubleshooting Chart, Temperature Gauge Inaccurate. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 8747 Temperature Gauge: Component Tests and General Diagnostics TROUBLESHOOTING Tester tool No. 021-00055 or equivalent should be used to diagnose these type of gauges. When troubleshooting, refer to pertaining pinpoint test. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic Engine Coolant Temperature Sender: Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Engine Coolant Temperature Sender <--> [Temperature Sensor (Gauge)] > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic > Page 8752 6. In the Remarks Section, write "Returned per TSB 95-13-2". 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 FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation PURPOSE The Voltmeter displays the current battery/charging system voltage to the driver. OPERATION The Voltmeter 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. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation > Page 8756 Volt Meter Gauge: Testing and Inspection 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 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Locations Water In Fuel Sensor: Locations Engine View The Water In Fuel Sensor is located at the top LH side of the engine. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > With E4OD Transmission Backup Lamp Switch: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > With E4OD Transmission > Page 8767 Backup Lamp Switch: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > With E4OD Transmission Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > With E4OD Transmission > Page 8770 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Page 8771 Backup Lamp Switch: Testing and Inspection Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 8780 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 8786 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8789 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8790 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8791 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8792 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8793 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8794 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8795 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8796 Brake Lamp: Electrical Diagrams Turn/Stop/Hazard Lamps (Part 1 Of 3) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8797 Turn/Stop/Hazard Lamps (Part 2 Of 3) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8798 Turn/Stop/Hazard Lamps (Part 3 Of 3) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake ON/OFF Switch <--> [Brake Light Switch] > Component Information > Diagrams Brake ON/OFF Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Brake ON/OFF Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 8802 Brake ON/OFF Switch: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect battery ground cable. Fig. 3 Stop Light Switch Replacement 2. Lift locking tab, then disconnect electrical connector from switch. 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. NOTE: Ensure stop light switch wires are of sufficient length to allow full travel of the brake pedal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 8811 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 96818 > Apr > 96 > A/T - Shifts From Park Without Brake Pedal Depression Center Mounted Brake Lamp: Customer Interest A/T - Shifts From Park Without Brake Pedal Depression Article No. 96-8-18 04/08/96 TRANSMISSION - ALL - VEHICLE CAN BE SHIFTED OUT OF "PARK" WITHOUT DEPRESSING BRAKE PEDAL - ECONOLINE CUTAWAYS ONLY AND F-SERIES BUILT THROUGH 2/28/95 LIGHT TRUCK: 1994-95 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES ISSUE: The customer may be able to shift the vehicle out of "Park" without depressing the brake pedal on some vehicles. This may occur if no high mount stoplamp is installed or the bulb filament is either missing or open, simulating the brake pedal being depressed. ACTION: Install a jumper harness with a resistor to simulate the presence of a high mount stoplamp or replace the high mount stoplamp if the bulb is open. Refer to the following Service Procedure for details. SERVICE PROCEDURE - ECONOLINE 1. If a high mount stoplamp is installed, check to make sure the bulb filament is not missing or open. Repair as required. 2. Locate the -14A200- wire harness along the B-pillar behind the driver's seat. 3. Locate brake test connector C358, Figure 1. This is a 2-way gray connector. 4. Install the jumper into the connector. 5. Wrap the main body wire harness with polyken tape. This will hold the connector in place and prevent any rattles of the connector to the B-pillar. SERVICE PROCEDURE - F-SERIES 1. Check to make sure the high mount stoplamp bulb filament is not missing or open. Repair as required. 2. Locate the -14334- wire harness in the rear of the cab near the center high mount stoplamp. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 96818 > Apr > 96 > A/T - Shifts From Park Without Brake Pedal Depression > Page 8816 3. Plug the jumper harness into the connector that would plug into the center high mount stoplamp. Wrap the jumper and connector with polyken tape and tape to inner sheet metal. This will hold the connector in place and prevent any rattles of the connector. PART NUMBER PART NAME F6TZ-13A409-AA Jumper Harness (F-Series) F5UZ-13A427-AB Jumper Harness (Econoline) E6DZ-13466-B High Mount Stoplamp Bulb (Obtain Locally) Polyken Tape OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960818A Add Jumper Harness Or 0.3 Hr. Replace Cab High Mount Stoplamp Bulb DEALER CODING CONDITION BASIC PART NO. CODE 14A200 79 OASIS CODES: 203000, 203200, 301000, 503300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 8822 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 96818 > Apr > 96 > A/T - Shifts From Park Without Brake Pedal Depression Center Mounted Brake Lamp: All Technical Service Bulletins A/T - Shifts From Park Without Brake Pedal Depression Article No. 96-8-18 04/08/96 TRANSMISSION - ALL - VEHICLE CAN BE SHIFTED OUT OF "PARK" WITHOUT DEPRESSING BRAKE PEDAL - ECONOLINE CUTAWAYS ONLY AND F-SERIES BUILT THROUGH 2/28/95 LIGHT TRUCK: 1994-95 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES ISSUE: The customer may be able to shift the vehicle out of "Park" without depressing the brake pedal on some vehicles. This may occur if no high mount stoplamp is installed or the bulb filament is either missing or open, simulating the brake pedal being depressed. ACTION: Install a jumper harness with a resistor to simulate the presence of a high mount stoplamp or replace the high mount stoplamp if the bulb is open. Refer to the following Service Procedure for details. SERVICE PROCEDURE - ECONOLINE 1. If a high mount stoplamp is installed, check to make sure the bulb filament is not missing or open. Repair as required. 2. Locate the -14A200- wire harness along the B-pillar behind the driver's seat. 3. Locate brake test connector C358, Figure 1. This is a 2-way gray connector. 4. Install the jumper into the connector. 5. Wrap the main body wire harness with polyken tape. This will hold the connector in place and prevent any rattles of the connector to the B-pillar. SERVICE PROCEDURE - F-SERIES 1. Check to make sure the high mount stoplamp bulb filament is not missing or open. Repair as required. 2. Locate the -14334- wire harness in the rear of the cab near the center high mount stoplamp. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 96818 > Apr > 96 > A/T - Shifts From Park Without Brake Pedal Depression > Page 8827 3. Plug the jumper harness into the connector that would plug into the center high mount stoplamp. Wrap the jumper and connector with polyken tape and tape to inner sheet metal. This will hold the connector in place and prevent any rattles of the connector. PART NUMBER PART NAME F6TZ-13A409-AA Jumper Harness (F-Series) F5UZ-13A427-AB Jumper Harness (Econoline) E6DZ-13466-B High Mount Stoplamp Bulb (Obtain Locally) Polyken Tape OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960818A Add Jumper Harness Or 0.3 Hr. Replace Cab High Mount Stoplamp Bulb DEALER CODING CONDITION BASIC PART NO. CODE 14A200 79 OASIS CODES: 203000, 203200, 301000, 503300 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Mounted Brake Lamp: > 961215 > Mar > 96 > Alarm System Sounds in Error Anti-Theft Hood Switch: All Technical Service Bulletins Alarm System - Sounds in Error Article No. 96-12-15 06/03/96 ANTI THEFT PROTECTION SYSTEM - ALARM SOUNDS IN ERROR - HOOD SWITCH POSITIONED TOO LOW LIGHT TRUCK: 1995-96 ECONOLINE ISSUE: The anti-theft alarm may sound in error on some vehicles. This may be caused by the sheet metal height variation in the cowl top where the anti-theft hood switch is located. ACTION: Adjust the anti-theft hood switch upward approximately 6 mm (0.25") to compensate for the sheet metal variation (Figure 1). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 961215A Adjust Hood Switch 0.2 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A434 36 OASIS CODES: 112000 203200, 205000, 206000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions Courtesy Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8842 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8843 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8844 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8845 ELECTRICAL SYMBOLS Electrical Symbols Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8846 Electrical Symbols VACUUM SYMBOLS Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8847 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8848 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8849 Courtesy Lamp: Electrical Diagrams Courtesy Lamps (Part 1 Of 6) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8850 Courtesy Lamps (Part 2 Of 6) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8851 Courtesy Lamps (Part 3 Of 6) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8852 Courtesy Lamps (Part 4 Of 6) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8853 Courtesy Lamps (Part 5 Of 6) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8854 Courtesy Lamps (Part 6 Of 6) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamps Module <--> [Daytime Running Lamp Control Unit] > Component Information > Locations Daytime Running Lamps Module: Locations Engine Compartment View The Daytime Running Lamps Module is located at the lower RH front of engine, near horns. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamps Module <--> [Daytime Running Lamp Control Unit] > Component Information > Locations > Page 8859 Daytime Running Lamps Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations Full Body View (Part 2 Of 2) The Electronic Flasher is located behind LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch (C217) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 8867 Hazard Warning Switch: Testing and Inspection Multi-Function Switch - Component Testing Procedure Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 8868 Wiper/Washer Switch - Terminal Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 8869 Multi-Function Switch - Schematic - Dimmer, Flash-to-Pass, Turn/Hazard Portion Of Multi-Function Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 8870 Hazard Warning Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams Multi-Function Switch (C218) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8875 Headlamp Dimmer Switch: Testing and Inspection Multi-Function Switch - Component Testing Procedure Wiper/Washer Switch - Terminal Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8876 Multi-Function Switch - Schematic - Dimmer, Flash-to-Pass, Turn/Hazard Portion Of Multi-Function Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8877 Headlamp Dimmer Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Main Light Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8881 Main Light Switch: Testing and Inspection Main Light Switch - Component Testing Procedure Main Light Switch - Terminal Locations Main Light Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8882 Main Light Switch: Service and Repair REMOVAL AND INSTALLATION 1. Remove engine cover. 2. Remove ash tray retainer attaching screws, then remove retainer. 3. Remove steering column center and left snap molding. 4. Remove cigar lighter element. Headlamp Switch 5. Remove headlamp switch knob and shaft by inserting a hooked tool into knob slot to depress spring, Fig. 2. 6. Unscrew bezel from instrument panel finish panel. 7. Remove steering column opening cover attaching screws, then the cover. 8. Remove 6 screws and steering column lower reinforcement. 9. Remove instrument cluster finish panel attaching screws. 10. Pull finish panel rearward, unsnap panel retainers, then disconnect panel electrical connectors. 11. Remove headlamp control shaft by depressing release button on switch housing with shaft in full On position, then pull shaft from switch. 12. Remove switch attaching nut, remove switch, then disconnect switch electrical connector. 13. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Engine Compartment View The Horn Relay is located on the driver's side of the engine compartment, in engine compartment fuse box. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8887 Horn Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations > Cutaways Interior Lighting Module: Locations Cutaways The Illuminated Entry Module is located behind LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations > Cutaways > Page 8892 Interior Lighting Module: Locations Except Cutaways Full Body View (Part 1 Of 3) The Illuminated Entry Module is located behind LH "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 8893 Illuminated Entry Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamps Module <--> [Daytime Running Lamp Control Unit] > Component Information > Locations Daytime Running Lamps Module: Locations Engine Compartment View The Daytime Running Lamps Module is located at the lower RH front of engine, near horns. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamps Module <--> [Daytime Running Lamp Control Unit] > Component Information > Locations > Page 8898 Daytime Running Lamps Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Engine Compartment View The Horn Relay is located on the driver's side of the engine compartment, in engine compartment fuse box. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8902 Horn Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Cutaways Interior Lighting Module: Locations Cutaways The Illuminated Entry Module is located behind LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Cutaways > Page 8907 Interior Lighting Module: Locations Except Cutaways Full Body View (Part 1 Of 3) The Illuminated Entry Module is located behind LH "B" pillar. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations > Page 8908 Illuminated Entry Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay Trailer Backup Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 8913 Trailer Battery Charge Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 8914 Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > With E4OD Transmission Backup Lamp Switch: Locations With E4OD Transmission Full Body View (Part 2 Of 2) The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > With E4OD Transmission > Page 8920 Backup Lamp Switch: Locations With 4R70W Transmission The Transmission Range Sensor is located at the LH side of transmission. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > With E4OD Transmission Transmission Range Sensor (With E4OD Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > With E4OD Transmission > Page 8923 Transmission Range Sensor (With 4R70W Transmission) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 8924 Backup Lamp Switch: Testing and Inspection Transmission Range Sensor - Component Testing Procedure Transmission Range Sensor - Terminal Locations (With E4OD Transmission) Transmission Range Sensor - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake ON/OFF Switch <--> [Brake Light Switch] > Component Information > Diagrams Brake ON/OFF Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake ON/OFF Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 8928 Brake ON/OFF Switch: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect battery ground cable. Fig. 3 Stop Light Switch Replacement 2. Lift locking tab, then disconnect electrical connector from switch. 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. NOTE: Ensure stop light switch wires are of sufficient length to allow full travel of the brake pedal. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Multi-Function Switch (C217) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 8932 Hazard Warning Switch: Testing and Inspection Multi-Function Switch - Component Testing Procedure Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 8933 Wiper/Washer Switch - Terminal Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 8934 Multi-Function Switch - Schematic - Dimmer, Flash-to-Pass, Turn/Hazard Portion Of Multi-Function Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 8935 Hazard Warning Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Multi-Function Switch (C218) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8939 Headlamp Dimmer Switch: Testing and Inspection Multi-Function Switch - Component Testing Procedure Wiper/Washer Switch - Terminal Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8940 Multi-Function Switch - Schematic - Dimmer, Flash-to-Pass, Turn/Hazard Portion Of Multi-Function Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 8941 Headlamp Dimmer Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Main Light Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8945 Main Light Switch: Testing and Inspection Main Light Switch - Component Testing Procedure Main Light Switch - Terminal Locations Main Light Switch - Schematic Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 8946 Main Light Switch: Service and Repair REMOVAL AND INSTALLATION 1. Remove engine cover. 2. Remove ash tray retainer attaching screws, then remove retainer. 3. Remove steering column center and left snap molding. 4. Remove cigar lighter element. Headlamp Switch 5. Remove headlamp switch knob and shaft by inserting a hooked tool into knob slot to depress spring, Fig. 2. 6. Unscrew bezel from instrument panel finish panel. 7. Remove steering column opening cover attaching screws, then the cover. 8. Remove 6 screws and steering column lower reinforcement. 9. Remove instrument cluster finish panel attaching screws. 10. Pull finish panel rearward, unsnap panel retainers, then disconnect panel electrical connectors. 11. Remove headlamp control shaft by depressing release button on switch housing with shaft in full On position, then pull shaft from switch. 12. Remove switch attaching nut, remove switch, then disconnect switch electrical connector. 13. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch (C217) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 8950 Turn Signal Switch: Testing and Inspection Multi-Function Switch - Component Testing Procedure Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 8951 Wiper/Washer Switch - Terminal Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 8952 Multi-Function Switch - Schematic - Dimmer, Flash-to-Pass, Turn/Hazard Portion Of Multi-Function Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 8953 Turn Signal Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement Part Article No. 01-19-4 10/01/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES 1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 201000, 201200 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay Trailer Backup Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 8962 Trailer Battery Charge Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Trailer Backup Lamp Relay > Page 8963 Trailer Running Lamps Relay Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations Full Body View (Part 2 Of 2) The Electronic Flasher is located behind LH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch (C217) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 8971 Turn Signal Switch: Testing and Inspection Multi-Function Switch - Component Testing Procedure Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 8972 Wiper/Washer Switch - Terminal Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 8973 Multi-Function Switch - Schematic - Dimmer, Flash-to-Pass, Turn/Hazard Portion Of Multi-Function Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 8974 Turn Signal Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Updated Replacement Part Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Updated Replacement Part Article No. 01-19-4 10/01/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1990-1995 ESCORT 1990-2000 CROWN VICTORIA 1991 TAURUS 1992-1995 E SERIES 1994 F-150, F-250, F-350 2000-2001 F-150, SUPER DUTY F SERIES 2001 EXCURSION LINCOLN: 1888-1989 MARK VII 2000-2001 TOWN CAR 2002 BLACKWOOD MERCURY: 1990-1995 GRAND MARQUIS, TRACER 1993-1998 VILLAGER ISSUE This article is to provide information on replacement hood lamp switches. The 14 degree Mercury style hood switches will no longer be available. Replacement 14 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 14 degree Mercury switch with new 14 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 201000, 201200 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > With Power Door Locks Power Window Switch: Diagrams With Power Door Locks Master Window/Door Lock Control Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > With Power Door Locks > Page 8986 RH Power Door Lock/Window Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > With Power Door Locks > Page 8987 Power Window Switch: Diagrams Without Power Door Locks LH Power Window Switch RH Power Window Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Power Windows <--> [Windows] > Power Window Switch > Component Information > Diagrams > With Power Door Locks Power Window Switch: Diagrams With Power Door Locks Master Window/Door Lock Control Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Power Windows <--> [Windows] > Power Window Switch > Component Information > Diagrams > With Power Door Locks > Page 8993 RH Power Door Lock/Window Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Power Windows <--> [Windows] > Power Window Switch > Component Information > Diagrams > With Power Door Locks > Page 8994 Power Window Switch: Diagrams Without Power Door Locks LH Power Window Switch RH Power Window Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Power Windows <--> [Windows] > Window Glass > Component Information > Technical Service Bulletins > Windshield/Interior Glass - Fog/Film Window Glass: Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Power Windows <--> [Windows] > Window Glass > Component Information > Technical Service Bulletins > Windshield/Interior Glass - Fog/Film > Page 8999 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Power Windows <--> [Windows] > Window Regulator > Component Information > Technical Service Bulletins > Customer Interest for Window Regulator: > 95179 > Aug > 95 > Front Door Window Regulator - Rattles Window Regulator: Customer Interest Front Door Window Regulator - Rattles Article No. 95-17-9 08/28/95 ^ DOOR - FRONT DOOR WINDOW REGULATOR "RATTLE" - VEHICLES BUILT FROM 12/1/94 THROUGH 1/31/95 ^ NOISE - "RATTLE" FROM FRONT DOOR - VEHICLES BUILT FROM 12/1/94 THROUGH 1/31/95 LIGHT TRUCK: 1995 ECONOLINE ISSUE: The window regulator cable may contact the inner door sheet metal causing a rattle or slap noise on some vehicles. This may be due to mispositioned foam along the cable. ACTION: Remove the front door panel and install foam tape along the cable where it is contacting the inner sheet metal (Figure 1). This will cushion the cable and prevent the cable from directly contacting the sheet metal. Refer to the 1995 Econoline Service Manual, Page 01-05-09, for door panel removal and installation procedures. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 951709AT Repair Rattle - Both Doors 0.8 Hr. 951709A Repair Rattle - One (1) Door 0.5 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1523200 OR 1523201 33 OASIS CODES: 102000, 702000, 702300, 703000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Power Windows <--> [Windows] > Window Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Regulator: > 95179 > Aug > 95 > Front Door Window Regulator - Rattles Window Regulator: All Technical Service Bulletins Front Door Window Regulator - Rattles Article No. 95-17-9 08/28/95 ^ DOOR - FRONT DOOR WINDOW REGULATOR "RATTLE" - VEHICLES BUILT FROM 12/1/94 THROUGH 1/31/95 ^ NOISE - "RATTLE" FROM FRONT DOOR - VEHICLES BUILT FROM 12/1/94 THROUGH 1/31/95 LIGHT TRUCK: 1995 ECONOLINE ISSUE: The window regulator cable may contact the inner door sheet metal causing a rattle or slap noise on some vehicles. This may be due to mispositioned foam along the cable. ACTION: Remove the front door panel and install foam tape along the cable where it is contacting the inner sheet metal (Figure 1). This will cushion the cable and prevent the cable from directly contacting the sheet metal. Refer to the 1995 Econoline Service Manual, Page 01-05-09, for door panel removal and installation procedures. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 951709AT Repair Rattle - Both Doors 0.8 Hr. 951709A Repair Rattle - One (1) Door 0.5 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1523200 OR 1523201 33 OASIS CODES: 102000, 702000, 702300, 703000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: Customer Interest Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 9021 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: All Technical Service Bulletins Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 9027 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Windshield: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 9032 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure Windshield: All Technical Service Bulletins Windshield - Material Usage Procedure Article No. 95-12-1 06/19/95 GLASS - WINDSHIELD - URETHANE MOUNTED GLASS MATERIAL USAGE PROCEDURE SERVICE TIP. FORD 1981-95 ESCORT 1983-95 THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1990-95 CROWN VICTORIA 1995-95 ASPIRE 1995 CONTOUR, MUSTANG LINCOLN-MERCURY 1982-95 CONTINENTAL 1983-95 COUGAR 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1990-95 GRAND MARQUIS, TOWN CAR 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE LIGHT TRUCK 1983-95 RANGER 1984-90 BRONCO II 1986-95 AEROSTAR 1987-95 BRONCO, F-150-350 SERIES, F-47 1992-95 ECONOLINE 1993-95 VILLAGER 1995 WINDSTAR ISSUE: Essex windshield replacement products have a limited shelf life. Products should be discarded if they have exceeded their shelf life. ACTION: Refer to the following text to decode the manufacturing (batch) date from the container. Also, refer to the Service Procedure for proper installation procedures. HOW TO READ ESSEX BATCH NUMBERS Example: JL158601AA Year: J Month: L Day: 15 Essex ARG: 8601 Batch: AA This batch was made December 15, 1995 at the Essex plant, batch sequence AA. Monthly Code Guide: ^ A - January ^ B - February ^ C - March ^ D - April Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure > Page 9037 ^ E - May ^ F - June ^ G - July ^ H - August ^ I - September ^ J - October ^ K - November ^ L December Year Code Guide: ^ J - 1995 ^ K - 1996 ^ L - 1997 ^ M - 1998 URETHANE MOUNTED GLASS MATERIAL USAGE PROCEDURE REMOVAL 1. If necessary, remove the windshield wiper mounting arm, pivot shafts and leaf screen along cowl. Remove the inside rear view mirror, all windshield garnish mouldings, A-pillar mouldings and lower headliner. 2. Use Rotunda Interior Cut-Out Knife (164-R2450 or 164-R2451) or equivalent to cut urethane. Refer to the manufacturer's instructions when using tool. CAUTION: USE CARE WHEN CUTTING THROUGH SEAL TO AVOID DAMAGE TO THE INSTRUMENT PANEL, REAR PACKAGE TRAY, HEADLINER OR INTERIOR TRIM. 3. Remove glass from vehicle using a suitable glass removal tool. INSTALLATION 1. Trim the urethane left on the flange with a utility knife or razor blade until the surface is smooth and free of cuts. Even up the urethane remaining on the pinch weld so it is all at the same level (approximately 1/16" or 1.6 mm). 2. Apply Essex Urethane Pinchweld Primer U-413 to any sheet metal that has been exposed along the pinch weld. Let dry for a minimum of 6-10 minutes before proceeding. Do not apply primer to existing urethane bead. 3. Properly align glass to body. Place the glass in the opening and center it from top to bottom and side to side with about equal clearance on all sides. Using masking tape or crayon, make alignment points on each of the four (4) sides of the glass and body. 4. Remove the windshield from the vehicle and place it inside up, on a low stable work surface. 5. Clean the glass with a non-alcohol based glass cleaner such as Essex Glass And Surface Cleaner GC-800. 6. Install rear view mirror bracket. Refer to the appropriate Service Manual for installation details. 7. Apply two (2) coats of Urethane Glass Prep U-401 to inner edge of the windshield. Wipe off material immediately after each application. NOTE: WIPE OFF URETHANE GLASS PREP U-401 IMMEDIATELY AFTER EACH APPLICATION. 8. Apply Essex Primer U-402 to the same glass area as U-401. Allow to dry 5 minutes. 9. Install foam dam tape on pinch weld, if required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure > Page 9038 10. Cut the nozzle of the Essex Urethane Auto Glass Adhesive U-4OOHV (Figure 1) and apply a triangular bead of urethane 5/8" (16 mm) by 3/8" (9 mm) wide around the perimeter of the pinch weld. 11. Install the glass into the opening taking care to align the marks previously designated. Press glass into place until full contact is made with urethane adhesive. Glass must be installed before urethane skins over. NOTE: BEFORE INSTALLING GLASS, OPEN THE WINDOWS TO PREVENT THE GLASS FROM BEING PUSHED OUT BY AIR PRESSURE IF A DOOR IS CLOSED. 12. If necessary, reinstall all mouldings and trim previously removed. CAUTION: WHEN REPLACING URETHANE INSTALLED GLASS, THE VEHICLE SHOULD NOT BE DRIVEN UNTIL THE URETHANE HAS CURED. THIS WILL PREVENT THE GLASS FROM BEING JARRED OUT OF POSITION AND HELP ENSURE APPROPRIATE WINDSHIELD RETENTION TO MEET SAFETY AND STRUCTURAL REQUIREMENTS. NOTE: USE ONLY URETHANE FOR SERVICE OF AIR AND WATER LEAKS ON URETHANE INSTALLED GLASS. These products are required for urethane mounted glass replacement: To locate the nearest distributor of Essex glass replacement products, contact the following locations: For North America or other: ^ Essex ARG ^ 555 Gaddis Blvd. ^ Dayton, Ohio 45403 ^ Phone Within North America: (800) 453-3779 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure > Page 9039 ^ Phone Outside North America: (513) 254-1550 ^ Fax: (513) 254-3779 For Europe: ^ Gurit-Essex AG ^ CH-8807 Freienbach ^ Phone: (055) 471121 ^ Fax: (055) 486738 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Windshield: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 9045 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure Windshield: All Technical Service Bulletins Windshield - Material Usage Procedure Article No. 95-12-1 06/19/95 GLASS - WINDSHIELD - URETHANE MOUNTED GLASS MATERIAL USAGE PROCEDURE SERVICE TIP. FORD 1981-95 ESCORT 1983-95 THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1990-95 CROWN VICTORIA 1995-95 ASPIRE 1995 CONTOUR, MUSTANG LINCOLN-MERCURY 1982-95 CONTINENTAL 1983-95 COUGAR 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1990-95 GRAND MARQUIS, TOWN CAR 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE LIGHT TRUCK 1983-95 RANGER 1984-90 BRONCO II 1986-95 AEROSTAR 1987-95 BRONCO, F-150-350 SERIES, F-47 1992-95 ECONOLINE 1993-95 VILLAGER 1995 WINDSTAR ISSUE: Essex windshield replacement products have a limited shelf life. Products should be discarded if they have exceeded their shelf life. ACTION: Refer to the following text to decode the manufacturing (batch) date from the container. Also, refer to the Service Procedure for proper installation procedures. HOW TO READ ESSEX BATCH NUMBERS Example: JL158601AA Year: J Month: L Day: 15 Essex ARG: 8601 Batch: AA This batch was made December 15, 1995 at the Essex plant, batch sequence AA. Monthly Code Guide: ^ A - January ^ B - February ^ C - March ^ D - April Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure > Page 9050 ^ E - May ^ F - June ^ G - July ^ H - August ^ I - September ^ J - October ^ K - November ^ L December Year Code Guide: ^ J - 1995 ^ K - 1996 ^ L - 1997 ^ M - 1998 URETHANE MOUNTED GLASS MATERIAL USAGE PROCEDURE REMOVAL 1. If necessary, remove the windshield wiper mounting arm, pivot shafts and leaf screen along cowl. Remove the inside rear view mirror, all windshield garnish mouldings, A-pillar mouldings and lower headliner. 2. Use Rotunda Interior Cut-Out Knife (164-R2450 or 164-R2451) or equivalent to cut urethane. Refer to the manufacturer's instructions when using tool. CAUTION: USE CARE WHEN CUTTING THROUGH SEAL TO AVOID DAMAGE TO THE INSTRUMENT PANEL, REAR PACKAGE TRAY, HEADLINER OR INTERIOR TRIM. 3. Remove glass from vehicle using a suitable glass removal tool. INSTALLATION 1. Trim the urethane left on the flange with a utility knife or razor blade until the surface is smooth and free of cuts. Even up the urethane remaining on the pinch weld so it is all at the same level (approximately 1/16" or 1.6 mm). 2. Apply Essex Urethane Pinchweld Primer U-413 to any sheet metal that has been exposed along the pinch weld. Let dry for a minimum of 6-10 minutes before proceeding. Do not apply primer to existing urethane bead. 3. Properly align glass to body. Place the glass in the opening and center it from top to bottom and side to side with about equal clearance on all sides. Using masking tape or crayon, make alignment points on each of the four (4) sides of the glass and body. 4. Remove the windshield from the vehicle and place it inside up, on a low stable work surface. 5. Clean the glass with a non-alcohol based glass cleaner such as Essex Glass And Surface Cleaner GC-800. 6. Install rear view mirror bracket. Refer to the appropriate Service Manual for installation details. 7. Apply two (2) coats of Urethane Glass Prep U-401 to inner edge of the windshield. Wipe off material immediately after each application. NOTE: WIPE OFF URETHANE GLASS PREP U-401 IMMEDIATELY AFTER EACH APPLICATION. 8. Apply Essex Primer U-402 to the same glass area as U-401. Allow to dry 5 minutes. 9. Install foam dam tape on pinch weld, if required. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure > Page 9051 10. Cut the nozzle of the Essex Urethane Auto Glass Adhesive U-4OOHV (Figure 1) and apply a triangular bead of urethane 5/8" (16 mm) by 3/8" (9 mm) wide around the perimeter of the pinch weld. 11. Install the glass into the opening taking care to align the marks previously designated. Press glass into place until full contact is made with urethane adhesive. Glass must be installed before urethane skins over. NOTE: BEFORE INSTALLING GLASS, OPEN THE WINDOWS TO PREVENT THE GLASS FROM BEING PUSHED OUT BY AIR PRESSURE IF A DOOR IS CLOSED. 12. If necessary, reinstall all mouldings and trim previously removed. CAUTION: WHEN REPLACING URETHANE INSTALLED GLASS, THE VEHICLE SHOULD NOT BE DRIVEN UNTIL THE URETHANE HAS CURED. THIS WILL PREVENT THE GLASS FROM BEING JARRED OUT OF POSITION AND HELP ENSURE APPROPRIATE WINDSHIELD RETENTION TO MEET SAFETY AND STRUCTURAL REQUIREMENTS. NOTE: USE ONLY URETHANE FOR SERVICE OF AIR AND WATER LEAKS ON URETHANE INSTALLED GLASS. These products are required for urethane mounted glass replacement: To locate the nearest distributor of Essex glass replacement products, contact the following locations: For North America or other: ^ Essex ARG ^ 555 Gaddis Blvd. ^ Dayton, Ohio 45403 ^ Phone Within North America: (800) 453-3779 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure > Page 9052 ^ Phone Outside North America: (513) 254-1550 ^ Fax: (513) 254-3779 For Europe: ^ Gurit-Essex AG ^ CH-8807 Freienbach ^ Phone: (055) 471121 ^ Fax: (055) 486738 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000 Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Instrument Panel View The Wiper Control Module is located behind RH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 9058 Wiper Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Multi-Function Switch (C218) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9063 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch - Component Testing Procedure Wiper/Washer Switch - Terminal Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9064 Wiper/Washer Switch - Schematic - Wiper/Washer Portion Of Multi-Function Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9065 Windshield Washer Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi-Function Switch (C218) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9069 Wiper Switch: Testing and Inspection Refer to images for windshield wiper switch continuity test. Testing should be performed with a suitable ohmmeter. Fig. 35 Windshield Wiper Switch Connector Terminal Indentification. Fig. 36 Windshield Wiper Switch Continuity Test. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9070 Fig. 37 Windshield Wiper Switch Continuity Test (Part 1 Of 2). Fig. 37 Windshield Wiper Switch Continuity Test (Part 2 Of 2). Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9071 Wiper Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. Torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Testing and Inspection Windshield Washer Pump: Testing and Inspection Fig. 38 Windshield Washer Pump Current Draw Test. Attach leads of a suitable ohmmeter to washer pump motor. Current draw should not exceed 4 amps or indicate less than 2 amps while the washer pump motor is pumping fluid. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Multi-Function Switch (C218) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9078 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch - Component Testing Procedure Wiper/Washer Switch - Terminal Locations Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9079 Wiper/Washer Switch - Schematic - Wiper/Washer Portion Of Multi-Function Switch Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 9080 Windshield Washer Switch: Service and Repair NOTE: On models with tilt column, unscrew the tilt lever and remove. REMOVAL AND INSTALLATION 1. Remove steering column shroud. 2. Remove switch to steering column tube casting attaching screws, then disengage switch from column. 3. Disconnect switch electrical connectors. NOTE: Do not damage PRNDL cable. 4. Remove switch assembly. 5. Reverse procedure to install. torque switch attaching screws to 18-27 inch lbs. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair Wiper Arm: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect battery ground cable. 2. Remove wiper pivot arms from the windshield wiper mounting arm and pivot shaft. 3. Remove the cowl vent seal and raise outer air inlet cowl slightly. 4. Remove the motor drive arm-to-linkage mounting arm and pivot shaft assembly retaining clip. 5. Remove washer jets from cowl vent grille. 6. Remove cowl grille. 7. Remove wiper motor attaching bolts, then remove motor. 8. Remove pivot body-to-cowl panel attaching screws, then the arm and pivot shaft assembly. 9. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Instrument Panel View The Wiper Control Module is located behind RH side of the instrument panel. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 9087 Wiper Control Module Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component Information > Diagrams Windshield Wiper Motor Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component Information > Diagrams > Page 9091 Windshield Wiper Motor: Testing and Inspection CAUTION: Use care when handling wiper motor. Damage to magnets may result from rough handling. 1. Disconnect windshield wiper mounting arm and pivot shaft from windshield wiper motor, then disconnect electrical plug from test motor. 2. Connect green lead from Rotunda Battery and Starter Tester tool No. 010-00725, or equivalent, to battery positive post. 3. Connect positive (red) lead from tester to common brush terminal. 4. Attach ground first to low-speed connection, then to high-speed connection at connector plug. In either case, current draw should not exceed 3.5 amperes. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Motor <--> [Wiper Motor] > Component Information > Diagrams > Page 9092 Windshield Wiper Motor: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect battery ground cable. 2. Remove wiper pivot arms from the windshield wiper mounting arm and pivot shaft. 3. Remove the cowl vent seal and outer air inlet cowl. 4. Remove the motor drive arm-to-linkage mounting arm and pivot shaft assembly retaining clip. 5. Disconnect wiper adapter and connecting arm clip then the wiper motor electrical connectors from motor brush cap and gearbox cover. 6. Remove wiper motor attaching bolts and the wiper motor. 7. Reverse procedure to install. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Multi-Function Switch (C218) Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9096 Wiper Switch: Testing and Inspection Refer to images for windshield wiper switch continuity test. Testing should be performed with a suitable ohmmeter. Fig. 35 Windshield Wiper Switch Connector Terminal Indentification. Fig. 36 Windshield Wiper Switch Continuity Test. Ford E 350 Van Workshop Manual (V8-7.3L DSL Turbo VIN F (1995)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9097 Fig. 37 Windshield Wiper Switch Continuity Test (Part 1 Of 2). Fig. 37 Windshield Wiper Switch Continuity Test (Part 2 Of 2).